SECTION5920

Section 5920
Installation Instructions
Spec. No. 582120100 (Model 1231V2)
Issue AC, August 11, 2004
VORTEX® POWER SYSTEM (VPS)

Intelligence Shelf
Expansion Shelf
Power Conversion Unit
Distribution Cabinet Assembly
208-240 VAC Single Phase Input
-48 VDC Output
Spec. No.: 582120100

Model: 1231V2
This document is property of Emerson Network Power, Energy Systems, North America, Inc. and contains confidential and proprietary information owned by Emerson Network Power, Energy
Systems, North America, Inc. Any copying, use, or disclosure of it without the written permission of Emerson Network Power, Energy Systems, North America, Inc. is strictly prohibited.
Section 5920 Installation Instructions
Issue AC, August 11, 2004 Spec. No. 582120100 (Model 1231V2)
The Emerson logo is a trademark and

service mark of Emerson Electric Co.
Lorain® is a registered trademark of Emerson

Network Power, Energy Systems, North America, Inc.
Vortex® is a registered trademark of Emerson

Network Power, Energy Systems, North America, Inc.
The products covered by this instruction manual are manufactured and/or

sold by Emerson Network Power, Energy Systems, North America, Inc.
If we can be of any further assistance to you,

please call one of our sales representatives
at (440) 288-1122.
For parts, service, depot repair, technical assistance, or training, call toll free:
one of the numbers listed on the Service Information Sheet (Section 4154).
Copyright © 2004, Emerson Network Power, Energy Systems, North America, Inc.
Installation Instructions Section 5920
Spec. No. 582120100 (Model 1231V2) Issue AC, August 11, 2004
STATIC WARNING
The printed circuit cards used in this equipment contain static sensitive components. The warnings listed below
must be observed to prevent damage to these components. Disregarding any of these warnings may result in
personal injury or damage to the equipment.
1. Do not insert or remove printed circuit cards with power applied. Wait at least 5 minutes after power is
turned off (or until power supplies have discharged to zero volts) before removing any circuit card.
2. Before touching any static sensitive component or printed circuit card containing such a component,
discharge all static electricity from yourself by wearing a wrist strap grounded through a one megohm
resistor. Some wrist straps, such as Emerson Network Power Part Number 631810600, have a built-in
one megohm resistor; no external resistor is necessary. Read and follow wrist strap manufacturer’s
instructions outlining use of a specific wrist strap.
3. Do not touch the traces or components on a printed circuit card containing static sensitive components.
Handle the printed circuit card only by the edges that do not have connector pads.
4. After removing a printed circuit card containing a static sensitive component, place the printed circuit card
only on conductive or anti-static material such as conductive foam, conductive plastic, or aluminum foil.
Do not use ordinary Styrofoam or ordinary plastic.
5. Store and ship static sensitive devices or printed circuit cards containing such components only in static
shielding containers.
6. If necessary to repair a printed circuit card containing a static sensitive component, wear an appropriately
grounded wrist strap, work on a conductive surface, use a grounded soldering iron, and use grounded
test equipment.
Static Warning Page 1 of 2

This Page Left Intentionally Blank
Page 2 of 2 Static Warning

FCC INFORMATION
The modem assembly of the Vortex® WinLink option (if installed) has been granted a registration number by the
Federal Communications Commission, under Part 68 rules and regulations for direct connection to the telephone
lines. In order to comply with these FCC rules, the following instructions must be carefully read and applicable
portions followed completely:
a) Direct connection to the telephone lines may be made only through the standard plug- ended cord
furnished to the utility-installed jack. No connection may be made to party or coin phone lines. Prior to
connecting the device to the telephone lines, you must:
b) Call your telephone company and inform them you have an FCC registered device you desire to connect
to their telephone lines. Give them the number(s) of the line(s) to be used, the make and model of the
device, the FCC registration number and ringer equivalence. This information will be found on the device
or enclosed with instructions as well as the jack suitable for your device.
c) After the telephone company has been advised of the above you may connect your device if the jack is
available, or after the telephone company has made the installation.
d) Repairs may be made only by the manufacturer or his authorized service agency. Unauthorized repairs
void registration and warranty. Contact seller or manufacturer for details of permissible user performed
routine repairs, and where and how to have other than routine repairs.
e) If, through abnormal circumstances, harm to the telephone lines is caused, it should be unplugged until it
can be determined if your device or the telephone line is the source. If your device is the source, it should
not be reconnected until necessary repairs are effected.
f) Should the telephone company notify you that your device is causing harm, the device should be
unplugged. The telephone company will, where practicable, notify you, that temporary discontinuance of
service may be required. However, where prior notice is not practicable, the telephone company may
temporarily discontinue service, if such action is reasonably necessary, in such cases the telephone
company must (A) Promptly notify you of such temporary discontinuance, (B) Afford you the opportunity
to correct the condition and (C) Inform you of your rights to bring a complaint to the FCC under their rules.
g) The telephone company may make changes in its communications facilities, equipment, operations or
procedures, where such action is reasonably required in the operation of its business and is not
inconsistent with FCC rules. If such changes can be reasonably expected to render any customer’s
devices incompatible with telephone company facilities, or require modification or alteration, or otherwise
materially affect its performance, written notification must be given to the user, to allow uninterrupted
service.
The following information is provided here and on a label attached to the outside of the Vortex WinLink option (if
installed).
JACK RINGER EQUIVALENCE FCC REGISTRATION NUMBER

RJ-11 0.2A B46USA-22429-MM-E
FCC Information Page 1 of 2

Page 2 of 2 FCC Information

TABLE OF CONTENTS
CONTENTS PAGE
CHAPTER 1 INSTALLING VPS............................................................................................. 1-1
Preface ............................................................................................................................................................. 1-1
Table of Contents............................................................................................................................................. 1-1
Installation Acceptance Checklist .................................................................................................................... 1-2
Mounting the Relay Racks ............................................................................................................................... 1-5
Mounting .................................................................................................................................................... 1-5
Ventilation Requirements .......................................................................................................................... 1-5
Mounting a Battery Charge Digital
Temperature Compensation Probe (if furnished) ............................................................................................ 1-6
Mounting a TXM (Multiple Probe
Concentrator Module) and Probes (if furnished).............................................................................................. 1-6
Mounting an Analog Battery Charge
Temperature Compensation Module (if furnished) .......................................................................................... 1-6
Installing VPS Fuseholder Modules (TPA-Type) and TPA-Type Fuses (if furnished) ..................................... 1-7
Installing TPL-Type Fuses ............................................................................................................................. 1-11
Installing VPS Circuit Breaker Modules (LEL1-Type) (if furnished) ............................................................... 1-13
Installing an AC Input Housing Assembly
(List 1, 10, and 11 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Individual (4) AC Input Branch Circuits) ........................................................ 1-16
588703600, and 588703700 - Single AC Input Branch Circuit)..................................................................... 1-20
(List 14 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Dual AC Input Branch Circuits)...................................................................... 1-24
(Spec. Nos. 588701300 and 588701400) ...................................................................................................... 1-28
Installing the MCA Modem, RS-232, RS-232/Modem,
RS-485, or Ethernet Interface Option (if furnished) ....................................................................................... 1-32
Installing Side Cover Panels .......................................................................................................................... 1-39
CHAPTER 2 SETTING VPS WIRING OPTIONS ................................................................... 2-1

Observe the Following Admonishments .......................................................................................................... 2-2
VPS Intelligence and Expansion Shelf
PCU Mounting Positions Identification Switches
(Spec. Nos. 588700701, 588700801, 588703600, and 588703700)............................................................... 2-3
(Spec. Nos. 588701300 and 588701400) ........................................................................................................ 2-8
VPS Intelligence Shelf Internal/External Voltage
Sensing Switch (Spec. No. 588701300) ........................................................................................................ 2-12
VPS Intelligence Shelf Internal/External System Voltage
Meter Reading Switch (Spec. No. 588701300).............................................................................................. 2-14
Table of Contents Page i

VPS Distribution Cabinet Assembly Internal/External Voltage Sensing

and Internal/External System Voltage Meter Reading Circuit Card............................................................... 2-17
VPS Distribution Cabinet Assembly Fuses and Fuse Alarm Polarity Circuit Card ........................................ 2-18
VPS Distribution Cabinet Assembly LVD (J5) and Shunt POD (J6) Jumpers ............................................... 2-19
VPS Distribution Cabinet Assembly Shunt POD Shunt Capacity Selection Switch ...................................... 2-22
VPS Distribution Cabinet Assembly Shunt POD
System/Subsystem Identification Jumper ...................................................................................................... 2-23
VPS Distribution Cabinet Assembly Low Voltage
Disconnect Circuit Card Identification Switch ................................................................................................ 2-26
MCA Local and Remote Access Lockout Switches ....................................................................................... 2-29
MCA Modem Interface Option "Number of Rings Before Answer" Jumper................................................... 2-32
MCA RS-232/Modem Interface Option "Number of Rings Before Answer" Jumper...................................... 2-35
MCA RS-232/Modem Interface Option "RS-232 Port Hardware Handshake" Jumper.................................. 2-37
Lorain® Battery Charge Temperature Compensation
Module Maximum Voltage Clamp Selection .................................................................................................. 2-40
CHAPTER 3 MAKING ELECTRICAL CONNECTIONS......................................................... 3-1

Observe the Following Admonishment ............................................................................................................ 3-3
Wiring Considerations ...................................................................................................................................... 3-3
Relay Rack Grounding Connection (Frame Ground)....................................................................................... 3-4
AC Input Grounding Connection
[to VPS Intelligence and Expansion Shelf(s)
Spec. Nos. 588700701, 588700801, 588703600, and 588703700] ................................................................ 3-5
AC Input Connections
(Lists 1, 10, and 11 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Individual (4) AC Input Branch Circuits)
[to VPS Intelligence and Expansion Shelf(s)] ................................................................................................ 3-10
(List 15 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - AC Input Line Cords)
(List 8 of Spec. Nos. 588700701 and 588700801 -
Single AC Input Branch Circuit)
(List 14 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Dual AC Input Branch Circuits)
AC Input Grounding Connections
Spec. Nos. 588701300 and 588701400] ....................................................................................................... 3-21
(Individual (4) AC Input Branch Circuits)
[to VPS Intelligence and Expansion Shelves
Spec. Nos. 588701300 and 588701400] ....................................................................................................... 3-23
Power Interconnections between VPS Intelligence and Expansion Shelf(s),
and VPS Distribution Cabinet Assembly [to VPS Intelligence and Expansion
Page ii Table of Contents

Shelf(s) Spec. Nos. 588700701, 588700801, 588703600, and 588703700,

and VPS Distribution Cabinet Assembly]....................................................................................................... 3-25
Shelf(s) Spec. Nos. 588701300 and 588701400,
and VPS Distribution Cabinet Assembly]....................................................................................................... 3-26
External Alarm, Reference, and Control Connections
[to VPS Intelligence Shelf and VPS Distribution Cabinet Assembly] ............................................................. 3-29
Battery Charge Digital Temperature Compensation Probe or
TXM (Multiple Probe Concentrator Module) Connection (if required) ..................................................... 3-30
Quick Connect Guide .............................................................................................................................. 3-31
Connections to Terminal Block TB1 on "Connector Assembly" Circuit Card
500441 (located inside the main VPS Distribution Cabinet Assembly) (all Lists) ................................... 3-46
Connections to J8 on VPS Intelligence Shelf .......................................................................................... 3-52
Connections to Terminal Blocks J1-J4 on Alarm Termination
Circuit Card 423356900 Procedure (582120100 Lists 40 and 41 only): ................................................. 3-77
Circuit Card 423356100 Procedure (582120100 Lists 40 and 41 only): ................................................. 3-80
Interconnections between Multiple VPS PCU Shelves Located in the Same Rack ...................................... 3-83
Interconnections between Multiple VPS PCU Shelves Located in Separate Racks ..................................... 3-85
Cable Connection(s) to the MCA Interface Option ........................................................................................ 3-87
MCA Modem Interface Option Connection
(if Modem or RS-232/Modem Interface Option furnished) ...................................................................... 3-87
MCA RS-485 Interface Option Connection
(if RS-485 Interface Option furnished)..................................................................................................... 3-89
(if RS-232 or RS-232/Modem Interface Option furnished) ...................................................................... 3-94
MCA Ethernet Interface Option Connection
(if Ethernet Interface Option furnished) ................................................................................................... 3-96
Alarm, Reference, and Control Interconnections between
VPS Intelligence Shelf and VPS Distribution Cabinet Assembly ................................................................... 3-96
Multiple VPS Distribution Cabinet Assemblies............................................................................................... 3-97
Load Connections [to VPS Distribution Cabinet Assembly(s)] ...................................................................... 3-99
Shunt Connections to GJ/218-Type Circuit Breakers E/W Internal Shunt ............................................ 3-100
Battery Connections [to VPS Distribution Cabinet Assembly(s)] ................................................................. 3-110
CHAPTER 4 INSTALLING THE PCUs AND INITIALLY STARTING VPS ............................ 4-1
Installing the PCUs........................................................................................................................................... 4-2
Spec. Nos. 588700701, 588700801, 588703600, and 588703700........................................................... 4-2
Spec. Nos. 588701300 and 588701400.................................................................................................... 4-2
Initially Starting, Configuring, and Checking System Operation ...................................................................... 4-2
Observe the Following Admonishment...................................................................................................... 4-2
Controls and Indicators.............................................................................................................................. 4-2
Initial Startup Preparation .......................................................................................................................... 4-2
Initially Starting the System ....................................................................................................................... 4-3
MCA Initialization ....................................................................................................................................... 4-3
Table of Contents Page iii

Initially Connecting Low Voltage Disconnect Circuits (if furnished) .......................................................... 4-8
Configuring the System ............................................................................................................................. 4-9
Setting Up the MCA Ethernet Option, if installed .................................................................................... 4-12
Checking Meter Operation....................................................................................................................... 4-16
Checking Adjustment and Calibration Values ......................................................................................... 4-18
Checking MCA Audible Alarm and MCA Audible Alarm Cutoff (if available) .......................................... 4-18
Checking Manual Test/Equalize and Manually Initiated Timed Test/Equalize........................................ 4-19
Checking Remote Test/Equalize ............................................................................................................. 4-22
Checking Remote High Voltage Shutdown ............................................................................................. 4-22
Checking Emergency Shutdown and Fire Alarm Disconnect.................................................................. 4-23
Checking Remote On/Off (TR) (if RS-485 Interface Option is installed) ................................................. 4-23
Checking High Voltage Shutdown ........................................................................................................... 4-24
Checking AC Fail Alarm .......................................................................................................................... 4-25
Checking PCU Fail Alarm........................................................................................................................ 4-26
Checking Open Sense Alarm .................................................................................................................. 4-27
Checking Fuse Alarm/Circuit Breaker Alarm........................................................................................... 4-28
Checking System High Voltage Alarm 1 ................................................................................................. 4-30
Checking System High Voltage Alarm 2 ................................................................................................. 4-32
Checking System Battery On Discharge Alarm....................................................................................... 4-33
Checking System 50% Battery On Discharge (Very Low Voltage) Alarm............................................... 4-34
Checking System Current Alarm ............................................................................................................. 4-36
Checking Subsystem (if subsystem installed) High Voltage Alarm......................................................... 4-37
Checking Subsystem (if subsystem installed) Low Voltage Alarm.......................................................... 4-39
Checking Subsystem (if subsystem installed) Current Alarm ................................................................. 4-40
Checking Low Voltage Disconnect (if furnished)..................................................................................... 4-41
Checking System Status ......................................................................................................................... 4-45
Final Step................................................................................................................................................. 4-45
APPENDIX (a record of the changes made to this document)
Page iv Table of Contents

CHAPTER 1
INSTALLING VPS
PREFACE
This document (Section 5920) provides Installation Instructions for Vortex® Power
System (VPS) Model 1231V2, Spec. No. 582120100 (-48V version).
For User Instructions, refer to Section 5705 located on the CD (Electronic Documentation
Package) provided with your system.
Note: A Battery Thermal Runaway Management System may be furnished. For

installation information, refer to the Battery Thermal Runaway Management
System instructions (Section 5593), included in this manual.
TABLE OF CONTENTS
Preface ............................................................................................................................ 1-1
Installation Acceptance Checklist.................................................................................... 1-2
Mounting the Relay Racks............................................................................................... 1-5
Mounting ................................................................................................................... 1-5
Ventilation Requirements.......................................................................................... 1-5
Mounting a Battery Charge Digital
Temperature Compensation Probe (if furnished)............................................................ 1-6
Mounting a TXM (Multiple Probe
Concentrator Module) and Probes (if furnished) ............................................................. 1-6
Mounting an Analog Battery Charge
Temperature Compensation Module (if furnished).......................................................... 1-6
Installing VPS Fuseholder Modules (TPA-Type) and TPA-Type Fuses (if furnished) .... 1-7
Installing TPL-Type Fuses............................................................................................. 1-11
Installing VPS Circuit Breaker Modules (LEL1-Type) (if furnished) .............................. 1-13
588703600, and 588703700 - Individual (4) AC Input Branch Circuits)........................ 1-16
588703600, and 588703700 - Single AC Input Branch Circuit) .................................... 1-20
(List 14 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Dual AC Input Branch Circuits) ..................................... 1-24
(Spec. Nos. 588701300 and 588701400) ..................................................................... 1-28
Installing the MCA Modem, RS-232, RS-232/Modem,
RS-485, or Ethernet Interface Option (if furnished)....................................................... 1-32
Installing Side Cover Panels.......................................................................................... 1-39
Chapter 1. Installing VPS Page 1-1

INSTALLATION ACCEPTANCE CHECKLIST

Provided below is an Installation Acceptance Checklist. This checklist helps ensure
proper installation and initial operation of the system. As the procedures presented in
Chapters 1 through 4 of this manual are completed, check the appropriate box on this list.
If the procedure is not required to be performed for your installation site, also check the
box in this list to indicate that the procedure was read. When installation is done, ensure
that each block in this list has been checked. Some of these procedures may have been
factory performed for you.
Chapter 1
Relay Racks Mounted to the Floor
Battery Charge Digital Temperature Compensation Probe Mounted (if required)
TXM (multiple probe concentrator module) and Probes Mounted (if required)
Analog Battery Charge Temperature Compensation Module Mounted (if required)
VPS Fuseholder Modules and TPA-Type Fuses Installed in VPS Distribution Cabinet
Assembly (if required)
TPL-Type Fuses Installed in VPS Distribution Cabinet Assembly (if required)
VPS LEL1-Type Circuit Breaker Modules Installed in VPS Distribution Cabinet

Assembly (if required)
AC Input Housing Assembly Installed on Each VPS Intelligence and Expansion Shelf
Modem, RS-232, RS-232/Modem, RS-485, or Ethernet MCA Interface Option

Installed (if required)
Side Cover Panels Installed on Each VPS Intelligence and Expansion Shelf (if
required)
Chapter 2
VPS Intelligence and Expansion Shelf PCU Mounting Positions Identification

Switches Set to Proper Position (located inside VPS PCU Shelves)
VPS Intelligence and Expansion Shelf Internal/External Voltage Sensing Switch Set
to Proper Position (located inside VPS PCU Shelves) (V100ICAB Only)
VPS Intelligence and Expansion Shelf Internal/External System Voltage Meter

Reading Switch Set to Proper Position (located inside VPS PCU Shelves) (V100ICAB
Only)
VPS Distribution Cabinet Assembly Internal/External Voltage Sensing and

Internal/External System Voltage Meter Reading Circuit Card Oriented to Proper
Position (located on circuit card 500441)
Page 1-2 Chapter 1. Installing VPS

VPS Distribution Cabinet Assembly Fuses and Fuse Alarm Polarity Circuit Card
Oriented to Proper Position (located on circuit card 500441)
VPS Distribution Cabinet Assembly LVD and Shunt POD Interface Jumpers Set
(located on circuit card 500441)
VPS Distribution Cabinet Assembly Shunt POD Shunt Capacity Selection Switch Set
to Proper Position (located on each Shunt POD)
VPS Distribution Cabinet Assembly Shunt POD System/Subsystem Identification

Jumper Set (located on each Shunt POD)
VPS Distribution Cabinet Assembly Low Voltage Disconnect Circuit Card

Identification Switch Set to Proper Position (located on each Low Voltage Disconnect
circuit card.
MCA Local Access Lockout Switch Set (accessed from side of VPS Intelligence
Shelf)
MCA Remote Access Lockout Switch Set (accessed from side of VPS Intelligence
Shelf)
Modem or RS-232/Modem Option (if furnished) "Number of Rings before Answer"

Jumper Set (located on Modem or RS-232/Modem circuit card)
RS-232/Modem Option (if furnished) "RS-232 Hardware Handshake" Jumper Set

(located on RS-232/Modem circuit card)
Battery Charge Temperature Compensation Module (if used) Maximum Voltage

Clamp Set (located on Battery Charge Temperature Compensation Module)
Chapter 3
Grounding Connection (Frame Ground) Made
AC Input Grounding Connections to each PCU Shelf Made
AC Input Connections to each PCU Shelf Made
Power Interconnections between VPS Intelligence and Expansion Shelf(s) and VPS
Distribution Cabinet Assemblies Made
External Alarm, Reference, and Control Connections Made
Interconnections Between Multiple VPS PCU Shelves Located in Same Rack Made
Interconnections Between Multiple VPS PCU Shelves Located in Separate Racks via
"Connector Assembly" Circuit Card 500441 Made (if required)
MCA Interface Option Cable Connection(s) Made (if installed)

Alarm, Reference, and Control Interconnections between VPS Intelligence Shelf and
VPS Distribution Cabinet Assembly via "Connector Assembly" Circuit Card 500441
Made
Alarm, Reference, and Control Interconnections between Multiple VPS Distribution

Cabinet Assemblies via "Connector Assembly" Circuit Card 500441 Made (if
required)
Load Connections Made
Battery Connections Made
Chapter 4
PCUs Installed
System Started, Configured, and Checked

MOUNTING THE RELAY RACKS

Mounting
All equipment cabinets are factory mounted to the relay racks specified when ordered.
The installer should be familiar with the installation requirements and techniques to be
used in mounting the relay racks to the floor.
This product is intended only for installation in a Restricted Access Location on or above
a non-combustible surface. A one (1) inch minimum clearance is required from the right
side (as viewed from the front) of the relay rack to a wall, other solid structure, or another
relay rack (other than the relay racks that are part of this system) for connector
installation/removal. Recommended minimum aisle space clearance is 2'6" for the front
of the relay rack and 2' for the rear of the relay rack.
Ventilation Requirements
Follow the requirements stated in the “Ventilation Requirements” section of the
appropriate System Application Guide (SAG) or Power Data Sheet (PD). These can be
accessed from the CD (Electronic Documentation Package) provided with your system..

MOUNTING A BATTERY CHARGE DIGITAL

TEMPERATURE COMPENSATION PROBE
(IF FURNISHED)
The Battery Charge Digital Temperature Compensation Probe is to be mounted near the
batteries.
Procedure:
1) Mount the Battery Charge Digital Temperature Compensation Probe to any

suitable surface located near the battery. One 1/4-inch hole is provided to mount
the probe.
MOUNTING A TXM (MULTIPLE PROBE

CONCENTRATOR MODULE) AND PROBES
(IF FURNISHED)
Refer to Section 5940.
MOUNTING AN ANALOG BATTERY CHARGE

TEMPERATURE COMPENSATION MODULE
(IF FURNISHED)
Note: Battery Charge Temperature Compensation Module Part No. 433867000 cannot
be used in systems with more than 20 PCUs.
The battery charge temperature compensation module is to be mounted on or near the

batteries.
Procedure:
1) Mount the battery charge temperature compensation module to any suitable

surface located on or near the battery. The module may be strapped, bolted, or
glued. In the mounted position, ensure that the pins of the module are not
touching any other object and that the pins cannot be inadvertently touched by
any personnel.
When considering a mounting location for the module, be aware that the module
senses ambient temperature through its aluminum base.

INSTALLING VPS FUSEHOLDER MODULES (TPA-TYPE)

AND TPA-TYPE FUSES (IF FURNISHED)
If VPS TPA-type fuseholder modules are not used in this system, skip this procedure.
Refer to Figure 3-12 for typical VPS Distribution Cabinet Assembly fuse/circuit breaker
position numbering schemes.
Note: This procedure is for VPS TPA-type fuseholder modules. Your system may
contain TPL type fuseholder modules, which are factory installed.
LOAD A Bus may be arranged with battery disconnect fuse(s)/circuit breakers.

Refer to the CIRCUIT DESIGNATION REFERENCE CARDS furnished inside the
cabinet assembly's front door for location of any battery disconnect fuse(s)/circuit
breakers installed.
Refer to the following procedure, and install VPS fuseholder modules and appropriately
sized TPA-type fuses into the respective modular mounting positions of the VPS
Distribution Cabinet Assembly(s). Record all fuse sizes on the card provided within the
VPS Distribution Cabinet Assembly(s).
VPS fuseholder modules and TPA-type fuses may have been factory installed for you. If
so, verify their positions and sizes. Verify the size of any fuse placed in the spare fuse
fuseholder located on a VPS fuseholder module.
Your VPS Distribution Cabinet Assembly contains up to four separate distribution bus
rows.
Note: Each bus in the VPS Distribution Cabinet Assembly is rated for a maximum
current of 500 amperes. The VPS Distribution Cabinet Assembly is rated up to
1200 amperes, maximum.
Procedure:
Note: Refer to Figures 1-1 and 1-2 as this procedure is performed.
1) Open the VPS Distribution Cabinet Assembly's front door by turning and holding
the captive fastener in the counterclockwise position.
Warning: If the following procedure is not followed, the fuseholder module or

mounting block may be damaged.
2) Ensure that the metal contact tabs on any VPS fuseholder module being installed
are not bent. Install a VPS fuseholder module into each desired VPS modular
fuseholder/circuit breaker mounting block position. Do this by orienting the
module over the desired mounting position so that the horizontal contact on the
back of the module is on the bottom, and the vertical contact is on the top. Grasp
the body of the module. Push the module squarely into its mounting position
(with equal pressure on both sides) until the top and bottom locking tabs on the
mounting block snap into the VPS fuseholder module.
3) When all VPS fuseholder modules are installed, install an appropriately sized
TPA-type fuse in each. Do this by removing the fuseholder portion from the
mounted fuseholder body by pulling it straight out. Be careful not to pull out the

fuseholder body. Install the fuse with the side containing the orange band placed
closest to the back of the fuseholder. Correct fuse placement is depicted on a
label located on the fuseholder. When done, push the fuseholder portion back
into the fuseholder body.
4) Record all fuse sizes installed on the card provided within the VPS Distribution
Cabinet Assembly.
5) If desired, a spare fuse may be placed in the spare fuse fuseholder located on
each VPS fuseholder module. Ensure that the spare fuse is of the correct type
and rating.
6) Close the VPS Distribution Cabinet Assembly's front door. The door can be shut
without turning the captive fasteners.

VPS MODULAR
FUSEHOLDER/
CIRCUIT BREAKER
MOUNTING BLOCK
ENSURE THESE TABS ARE NOT BENT
LOCKING TAB
VPS FUSEHOLDER MODULE
Figure 1-1
Installing a VPS Fuseholder Module (TPA-Type)

VPS MODULAR
FUSEHOLDER/
CIRCUIT BREAKER
MOUNTING BLOCK
ALTERNATE
LOCATION OF
SPARE FUSE
FUSEHOLDER
"ORANGE BAND"
VPS FUSEHOLDER MODULE

(Body Portion)
LABEL ON FUSEHOLDER
DEPICTING LOCATION OF
"ORANGE BAND"
FUSEHOLDER
PORTION
Figure 1-2
Installing a Fuse in a VPS Fuseholder Module (TPA-Type)

INSTALLING TPL-TYPE FUSES

If TPL-type fuses are not used in this system, skip this procedure.
Note: This procedure is for TPL-type fuses. Your system may contain other types of
fuses.
LOAD A Bus may be arranged with battery disconnect fuse(s)/circuit breakers.

breakers installed.
Refer to the following procedure, and install appropriately sized TPL-type fuses into the
respective fuseholders of the VPS Distribution Cabinet Assembly(s). Record all fuse
sizes on the card provided within the VPS Distribution Cabinet Assembly(s).
Fuses may have been factory installed for you. If so, verify their positions and sizes.
rows.
Procedure:
Note: Refer to Figure 1-3 as this procedure is performed.
1) Remove the fuseholder portion from the mounted fuseholder body by grasping its
handle and pulling it straight out. Install the TPL-type fuse into the fuseholder
portion. Secure the fuse with the flat washer, lock washer, and nut provided.
Recommended torque is 168 in-lbs. When done, push the fuseholder portion
securely back into the mounted fuseholder body.
2) Record all fuse sizes installed on the card provided within the VPS Distribution
Cabinet Assembly(s).
3) Ensure an alarm fuse is installed in the GMT-type fuseholder located adjacent to

the TPL-type fuseholder. The alarm fuse should be a Bussmann GMT 0.25
ampere alarm fuse. Part No. 248610200.
4) Ensure a safety fuse cover is install on the GMT alarm fuse.

Figure 1-3
Installing a TPL-Type Fuse

INSTALLING VPS CIRCUIT BREAKER

MODULES (LEL1-TYPE) (IF FURNISHED)
Caution: Circuit breakers with a 70 ampere or greater rating SHALL HAVE an
empty mounting position between it and any other overcurrent protective
device.
If VPS LEL1-type circuit breaker modules are not used in this system, skip this
procedure.
Refer to Figure 3-12 for typical VPS Distribution Cabinet Assembly fuse/circuit breaker
position numbering schemes.
Note: LOAD A Bus may be arranged with battery disconnect fuse(s)/circuit breakers.
breakers installed.
Refer to the following procedure, and install appropriately sized VPS circuit breaker
modules into the respective modular mounting positions of the VPS Distribution Cabinet
Assembly(s). Record all circuit breaker sizes on the card provided within the VPS
Distribution Cabinet Assembly(s).
VPS circuit breaker modules may have been factory installed for you. If so, verify their
positions and sizes.
rows.
Procedure:
Note: Refer to Figure 1-4 as this procedure is performed.
Warning: If the following procedure is not followed, the circuit breaker module
or mounting block may be damaged.
2) Ensure that any VPS circuit breaker module being installed is in the OFF
position, and is of the correct rating. Ensure that the metal contact tabs on any
VPS circuit breaker module being installed are not bent. Install an appropriately
sized VPS circuit breaker module into each desired VPS modular
fuseholder/circuit breaker mounting block position. Do this by orienting the
module over the desired mounting position so that the horizontal contact on the
back of the module is on the bottom, and the vertical contact is on the top. Grasp
the body of the module (do not grasp a circuit breaker module by its front tabs,
they may break off). Push the module squarely into its mounting position (with
equal pressure on both sides) until the top and bottom locking tabs on the
mounting block snap into the VPS circuit breaker module.

3) Record all circuit breaker sizes installed on the card provided within the VPS
Distribution Cabinet Assembly.
without turning the captive fasteners.

VPS MODULAR
FUSEHOLDER/
CIRCUIT BREAKER
MOUNTING BLOCK
ENSURE THESE TABS ARE NOT BENT
LOCKING TAB
VPS CIRCUIT BREAKER MODULE
DO NOT BREAK THESE TABS
Figure 1-4
Installing a VPS Circuit Breaker Module (LEL1-Type)

INSTALLING AN AC INPUT HOUSING ASSEMBLY

(LIST 1, 10, AND 11 OF SPEC. NOS. 588700701, 588700801,
588703600, AND 588703700 - INDIVIDUAL (4) AC INPUT BRANCH
CIRCUITS)
Note: The AC Input Housing Assembly must be installed after a VPS Intelligence or
Expansion Shelf is mounted to a relay rack.
One type of AC Input Housing Assembly is furnished (as ordered) with each VPS
Intelligence and Expansion Shelf.
The AC Input Housing Assembly furnished with 588700701, 588700801, 588703600, and
588703700 Lists 1, 10, and 11 provides a convenient method of connecting each PCU to
an AC input branch circuit in each VPS Intelligence or Expansion Shelf. This assembly
covers the rectangular opening provided on the shelf for AC input service, and provides
four holes for 3/4" conduit fittings.
The AC Input Housing Assembly consists of ...
(1) AC Input Housing Base
(1) AC Input Housing Cover
(1) Shield
A flat-blade screwdriver is required to install this assembly.
Procedure:
Danger: Ensure that AC and DC power sources are NOT connected to the VPS
Intelligence or Expansion Shelf.
Note: Install this assembly only after securing the VPS Intelligence or Expansion
Shelf to a relay rack.
Note: Refer to Figure 1-5A as this procedure is performed.
1) Locate the rectangular opening provided on the left side of the VPS Intelligence
or Expansion Shelf for AC input wiring (as viewed from the front).
2) Place the AC Input Housing Base over the rectangular opening of the VPS
Intelligence or Expansion Shelf, oriented as shown in Figure 1-5A.
3) Align the three (3) captive fasteners on the AC Input Housing Base with the three
(3) mounting holes in the VPS Intelligence or Expansion Shelf. Secure the AC
Input Housing Base to the VPS Intelligence or Expansion Shelf by tightening the
captive fasteners. Recommended torque is 6.0 in-lbs.
4) Place customer supplied conduit fittings in the holes of the AC Input Housing
Base.
5) After the AC input and frame ground connections have been made to the shelf
(as detailed in "Chapter 3. Making Electrical Connections"), place the Shield
onto the two (2) upper captive fasteners on the AC Input Housing, oriented as

shown in Figure 1-5A. Place the shield between the cabinet and the wiring (to
prevent wires from protruding into cabinet's rectangular opening).
(as detailed in "Chapter 3. Making Electrical Connections"), place the AC Input
Housing Cover onto the AC Input Housing Base. The cover fits inside the base.
First insert the tab side of the cover into the base. Align the tabs on the cover
into the corresponding openings on the base. Push the right side of the cover in
and to the right until the tabs protrude outside the openings in the base. Push
the left side of the cover in until the captive fasteners on the cover align with the
holes on the base. Secure the cover to the base with the captive fasteners.

SECURE AC INPUT HOUSING BASE

TO SHELF WITH CAPTIVE FASTENERS
LOCATED ON BASE (3) PLACES
GROUND
STUDS (4)
REAR OF INTELLIGENCE/
EXPANSION SHELF
(PARTIAL VIEW)
PLACE CUSTOMER
AC INPUT SUPPLIED 3/4"
HOUSING BASE CONDUIT FITTINGS
IN THESE (4) HOLES
ATTACHING
AC INPUT
HOUSING BASE
Figure 1-5A (continued on next page)
(Lists 1, 10, and 11 of Spec. Nos. 588700701, 588700801, 588703600, and 588703700)

INSERT TABS ON AC
INPUT HOUSING COVER
INTO CORRESPONDING
OPENINGS ON AC
INPUT HOUSING BASE
SHIELD
ATTACHING
AC INPUT
HOUSING COVER
AC INPUT
HOUSING COVER
SECURE COVER AC INPUT

TO BASE WITH HOUSING BASE
CAPTIVE FASTENERS
LOCATED ON COVER
(2) PLACES
INSTALLATION
COMPLETE
VIEW
Figure 1-5A (continued from previous page)

(Lists 1, 10, and 11 of Spec. Nos. 588700701, 588700801, 588703600, and 588703700)


(LIST 8, 12, AND 13 OF SPEC. NOS. 588700701, 588700801,
588703600, AND 588703700 - SINGLE AC INPUT BRANCH
CIRCUIT)
588703700 List 8, 12, and 13 provides a convenient method of connecting a single AC
input branch circuit (which is internally bused to all PCUs) to a VPS Intelligence or
Expansion Shelf. This assembly covers the rectangular opening provided on the shelf for
AC input service, and provides one hole for a 3/4" conduit fitting.
(8) Jumpers
Procedure:
Note: Refer to Figure 1-5B as this procedure is performed.
Note: Some installations require the wires supplied with the AC Input Housing
Assembly to be attached to TB1 on the VPS Intelligence or Expansion Shelf
first, before securing the assembly to the side of the shelf. An example is
when the PCU Shelf is mounted at the bottom of a relay rack that has a
triangular support member adjacent to the AC Input Housing Assembly
mounting location. In these instances, connect the supplied wires to the
appropriate terminals of TB1 on the PCU Shelf before mounting the assembly
to the PCU Shelf. Refer to the wiring procedure provided in "Chapter 3.
Making Electrical Connections".
Intelligence or Expansion Shelf, oriented as shown in Figure 1-5B.

4) Place customer supplied conduit fitting in the hole of the AC Input Housing Base.
5) Attach the wires of the AC Input Housing Assembly as described in "AC Input
Connections (List 8, 12, and 13 of Spec. No. 588700701, 588700801,
588703600, and 588703700 - Single AC Input Branch Circuit)" found in "Chapter
3. Making Electrical Connections".


PLACE CUSTOMER
SUPPLIED 3/4"
CONDUIT FITTING
IN THIS (1) HOLE
EXPANSION SHELF
GROUND
(PARTIAL VIEW) STUD (1) AC INPUT
HOUSING BASE
ATTACHING
AC INPUT
HOUSING BASE
Figure 1-5B (continued on next page)
(List 8, 12, and 13 of Spec. Nos. 588700701, 588700801, 588703600, and 588703700)

INSERT TABS ON AC
INPUT HOUSING COVER
INTO CORRESPONDING
OPENINGS ON AC
INPUT HOUSING BASE
ATTACHING
AC INPUT
HOUSING COVER
SEE "CHAPTER 3.
MAKING ELECTRICAL
CONNECTIONS" FOR
SECURE COVER ATTACHING WIRES
TO BASE WITH
CAPTIVE FASTENERS AC INPUT
LOCATED ON COVER HOUSING BASE
(2) PLACES
AC INPUT
HOUSING COVER
INSTALLATION
COMPLETE
VIEW
Figure 1-5B (continued from previous page)

(List 8, 12, and 13 of Spec. Nos. 588700701, 588700801, 588703600, and 588703700)


(LIST 14 OF SPEC. NOS. 588700701, 588700801, 588703600, AND
588703700 - DUAL AC INPUT BRANCH CIRCUITS)
588703700 List 14 provides a convenient method of connecting dual AC input branch
circuits (PCU 1 and PCU 3 are connected to branch 1, and PCU 2 and PCU 4 are
connected to branch 2) to a VPS Intelligence or Expansion Shelf. This assembly covers
the rectangular opening provided on the shelf for AC input service, and provides two
holes for 3/4" conduit fittings.
(16) Jumpers
Procedure:
Note: Refer to Figure 1-5C as this procedure is performed.
Note: Some installations require the wires supplied with the AC Input Housing
Assembly to be attached to TB1 on the VPS Intelligence or Expansion Shelf
first, before securing the assembly to the side of the shelf. An example is
when the PCU Shelf is mounted at the bottom of a relay rack that has a
triangular support member adjacent to the AC Input Housing Assembly
mounting location. In these instances, connect the supplied wires to the
appropriate terminals of TB1 on the PCU Shelf before mounting the assembly
to the PCU Shelf. Refer to the wiring procedure provided in "Chapter 3.
Making Electrical Connections".
Intelligence or Expansion Shelf, oriented as shown in Figure 1-5C.

Base.
5) Attach the wires of the AC Input Housing Assembly as described in "AC Input
Connections (List 14 of Spec. No. 588700701, 588700801, 588703600, and
588703700 - Dual AC Input Branch Circuits)" found in "Chapter 3. Making
Electrical Connections".


EXPANSION SHELF PLACE CUSTOMER
(PARTIAL VIEW) SUPPLIED 3/4"
CONDUIT FITTING
GROUND IN THESE (2) HOLES
STUD (1)
AC INPUT
HOUSING BASE
ATTACHING
AC INPUT
HOUSING BASE
Figure 1-5C (continued on next page)
(List 14 of Spec. Nos. 588700701, 588700801, 588703600, and 588703700)

INSERT TABS ON AC
INPUT HOUSING COVER
INTO CORRESPONDING
OPENINGS ON AC
INPUT HOUSING BASE
ATTACHING
AC INPUT
HOUSING COVER
SEE "CHAPTER 3.
MAKING ELECTRICAL
CONNECTIONS" FOR
SECURE COVER ATTACHING WIRES
TO BASE WITH
CAPTIVE FASTENERS AC INPUT
LOCATED ON COVER HOUSING BASE
(2) PLACES
AC INPUT
HOUSING COVER
INSTALLATION
COMPLETE
VIEW
Figure 1-5C (continued from previous page)

(List 14 of Spec. Nos. 588700701, 588700801, 588703600, and 588703700)


(SPEC. NOS. 588701300 AND 588701400)
An AC Input Housing Assembly is furnished with each VPS Intelligence and Expansion
Shelf. This assembly provides a convenient method of connecting each PCU to an AC
input branch circuit in each VPS Intelligence or Expansion Shelf. This assembly covers
the rectangular opening provided on the shelf for AC input service, and provides four
holes for 1/2" conduit fittings.
Procedure:
Note: Refer to Figure 1-5D as this procedure is performed.
Intelligence or Expansion Shelf, oriented as shown in Figure 1-5D.
3) Align the four (4) captive fasteners on the AC Input Housing Base with the four
captive fasteners.
Base.


GROUND
STUDS (4)
REAR OF VPS
INTELLIGENCE/
EXPANSION
SHELF
AC INPUT
HOUSING BASE
ATTACHING
AC INPUT
HOUSING BASE
Figure 1-5D (continued on next page)
(Spec. Nos. 588701300 and 588701400)

INSERT TABS ON AC
INPUT HOUSING COVER
INTO CORRESPONDING
OPENINGS ON AC
INPUT HOUSING BASE
SECURE COVER AC INPUT

TO BASE WITH HOUSING BASE
CAPTIVE FASTENERS
LOCATED ON COVER
(2) PLACES AC INPUT
HOUSING COVER
ATTACHING
AC INPUT
HOUSING COVER
Figure 1-5D (continued on next page, continued from previous page)
(Spec. Nos. 588701300 and 588701400)

PLACE CUSTOMER
SUPPLIED 1/2"
CONDUIT FITTINGS
IN THESE (4) HOLES
INSTALLATION
COMPLETE
VIEW
Figure 1-5D (continued from previous page)
(Spec. Nos. 588701300 and 588701400)

INSTALLING THE MCA MODEM, RS-232, RS-232/MODEM,

RS-485, OR ETHERNET INTERFACE OPTION (IF FURNISHED)
Admonishments
Danger: Installation of this kit should only be performed by a qualified technician

following approved safety procedures.
Performing the following procedure may expose technicians to hazards.

This procedure should be performed by qualified technicians familiar with
the hazards associated with this type of equipment. These hazards may
include shock, energy, and/or burns. To avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other jewelry.
c) Prior to contacting any uninsulated surface or termination, use a

voltmeter to verify that no voltage or the expected voltage is present.
d) Wear eye protection, and use recommended tools.
Warning: Before handling any circuit card, read and follow the instructions
contained on the Static Warning page located at the beginning of this
document.
Kit Description
These instructions provide step-by-step procedures to field install one of the following
MCA Interface Options onto the outside of a VPS Intelligence Shelf (MCA).
• MCA Modem Interface Option Kit (P/N 483215200)
• MCA RS-485 Interface Option Kit (P/N 483215400)
• MCA RS-232 Interface Option Kit (P/N 508977)
• MCA RS-232/Modem Interface Option Kit (P/N 514023 or 514128)
• MCA Ethernet Interface Option Kit (P/N 524669)
Note: Only one interface option (Modem, RS-485, RS-232, RS-232/Modem, or Ethernet)
can be installed on the MCA.
This procedure consists of...
• Setting any Associated Jumper Option
• Installing the Option
• Cable Connection to the Option
• Accessing the MCA via the Option

Tools Required
A cross-blade and flat-blade screwdriver are required to install the option.
Kit Contents
The following items are furnished as a part of this kit. Before starting the procedure,
check the items furnished against those listed to ensure that there are no shortages.
MCA Modem Interface Option (P/N 483215200)
(1) Ferrite Cable Clamp

(1) Modem Circuit Card (Part No. 486781300)
(1) Mounting Bracket
(2) 6-32 x 1/4" Screws
(2) 6-32 Lock Washers
(1) FCC Label
(1) Modem Label
(1) Disposable Static Wrist Strap
MCA RS-485 Interface Option (P/N 483215400)

(1) RS-485 Circuit Card (Part No. 486781400)
(2) 6-32 x 1/4" Screws
(1) RS-485 Label
MCA RS-232 Interface Option (P/N 508977)

(1) RS-232 Circuit Card (Part No. 486781700)
(2) 6-32 x 1/4" Screws
(1) RS-232 Label
MCA RS-232/Modem Interface Option (P/N 514128)
(1) Shelf Side Cover Dress Panel (w/ RS-232 Cutout) and Screws
(1) RS-232 Label for Dress Panel
(1) Pre-Assembled RS-232/Modem Assembly (Part No. 514023)
(see description below)

MCA RS-232/Modem Interface Option (P/N 514023)

(1) Pre-Assembled RS-232/Modem Assembly (Part No. 514023, includes P/N
513992 RS-232/Modem Circuit Card Assembly and Sheetmetal Housing)
MCA Ethernet Interface Option (P/N 524669)
(1) Pre-Assembled Ethernet Interface Assembly (Part No. 524669, includes P/N
524592 Ethernet Interface Circuit Card Assembly and Sheetmetal Housing)
Installation Procedure
The following are step-by-step procedures to install the kit. These procedures have been
written for ease of use and to minimize the possibility of contact with potentially
hazardous energy. These procedures should be performed in the sequence given, and
each step should be completely read and fully understood before performing that step.
All DANGERS, CAUTIONS, and WARNINGS encountered during these procedures must
be carefully read and observed. As each step of the procedures are completed, the block
adjacent to the respective step should be checked. This will minimize the possibility of
inadvertently skipping any steps. If the step is not required to be performed for your site,
also check the box to indicate that it was read.
Note: Refer to Figures 1-6 and 1-7 as this procedure is performed.
Note: When performing any step in these procedures which requires removal of existing
hardware, retain all hardware for use in subsequent steps, unless otherwise
stated.
Procedure
[ ] 1. Performing this procedure may activate external alarms. Do one of the following.
If possible, disable these alarms. If these alarms cannot be easily disabled,
notify the appropriate personnel to disregard any future alarms associated with
this system.
[ ] 2. Open the VPS Intelligence Shelf's front door by turning and holding the captive
fastener in the counterclockwise position.
[ ] 3. On the PCU installed in mounting position #3, place the Standby/Operate switch
to the "standby" position, then the Output Breaker (-48V PCU only) to the 0 "off"
position.
[ ] 4. On the PCU installed in mounting position #3, loosen the captive fasteners on the
front of the PCU. Use the handle provided on the front of the PCU, and pull the
PCU from the shelf. Support the bottom of the PCU as you pull it out.
[ ] 5. Remove MCA Input Power Fuse F2 located behind PCU mounting position #3.
[ ] 6. With an external voltmeter, verify plant voltage is correct (MCA is powered down
at this point).

Warning: Damage to the MCA Interface Option circuit card may result if the next
step is not followed.
[ ] 7. Connect an approved grounding strap to your wrist. Attach the other end to a
suitable ground.
[ ] 8. Modem Circuit Card Only: Before installing the Modem circuit card, set the
modem for 1 ring or 5 rings as described under "MCA Modem 'Number of Rings
before Answer' Jumper" in "Chapter 2. Setting VPS Wiring Options".
[ ] 9. RS-232/Modem Circuit Card Only: Before installing the RS-232/Modem

Assembly, set the modem for 1 ring or 5 rings as described under "MCA Modem
'Number of Rings before Answer' Jumper" in "Chapter 2. Setting VPS Wiring
Options".
[ ] 10. RS-232/Modem Circuit Card Only: Before installing the RS-232/Modem

Assembly, set the RS-232 Handshaking as required as described under "RS-232
Handshake Jumper" in "Chapter 2. Setting VPS Wiring Options".
[ ] 11. Secure the Modem, RS-232, or RS-485 circuit card to the supplied bracket as
shown in Figure 1-2. Use the hardware furnished with the option. Note that the
RS-232/Modem and Ethernet options are pre-asembled.
[ ] 12. Locate the option access cover on the right side (as viewed from the front) of the
VPS Intelligence Shelf. Loosen the two captive fasteners and remove the cover.
This cover will not be re-used, but should be saved if the option is ever removed.
[ ] 13. The Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option attaches to

the MCA circuit card now visible through the option access opening. The
Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option attaches to the
MCA circuit card via a connector that plugs into a mating connector containing a
set of pins on the MCA circuit card. Locate these mating connectors on the
Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option and the MCA
circuit card. Refer to Figures 1-6 or 1-7 for location.
[ ] 14. Hold the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option by the
edges of the mounting bracket. Orient the option over the option access opening
with the MCA mating connector at the bottom.
[ ] 15. Push the option into the option access opening, aligning the mating connectors
on the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet circuit card and
the MCA circuit card. You can observe the mating connectors by looking through
the front of the VPS Intelligence Shelf. Push the Modem, RS-232,
RS-232/Modem, RS-485, or Ethernet option in and down, ensuring the mating
connectors are properly aligned. You may need to push on the metal plate
mounting the MCA circuit card from the inside of the VPS Intelligence Shelf to
align the mating connectors. Secure the Modem, RS-232, RS-232/Modem,
RS-485, or Ethernet option to the VPS Intelligence Shelf by tightening the two
captive fasteners located on the mounting bracket.
[ ] 16. Adhere the supplied label(s) to the option mounting bracket as indicated in
Figures 1-6 or 1-7, if required.
[ ] 17. RS-232/Modem Circuit Card Only: Adhere the supplied RS-232 label to the
supplied shelf side cover dress panel (near the RS-232 cutout). Note that the kit

for the V100CAB VPS Intelligence Shelf is not supplied with a new side cover
dress panel due to mechanical restrictions.
[ ] 18. Replace MCA Input Power Fuse F2.
[ ] 19. Remove the grounding wrist strap.
[ ] 20. Reinstall the PCU, if removed during this procedure, as detailed below.
a) Ensure that the Standby/Operate switch on the PCU is in the "standby"

position.
b) Ensure that the Output Breaker (-48V PCU only) on the PCU is in the 0 "off"
position.
c) Slide the PCU into its mounting position. Secure the PCU to the shelf by
tightening the captive fasteners located on the front panel.
[ ] 21. On the PCU, place the Standby/Operate switch to the I "operate" position, then
the Output Breaker (-48V PCU only) to the I "on" position.
[ ] 22. Close the VPS Intelligence Shelf's front door. The door can be shut without
turning the captive fastener.
[ ] 23. After making the cable connection to the Modem, RS-232, RS-232/Modem, or
RS-485 circuit card, as described in "Chapter 3. Making Electrical Connections",
install the supplied ferrite cable clamp onto the cable near the VPS Intelligence
Shelf.
[ ] 24. Enable the external alarms, or notify appropriate personnel that this procedure is
finished.
[ ] 25. Ensure that there are no local or remote alarms active on the system.

FRONT OF VPS
INTELLIGENCE SHELF
SPEC. NO. 588700701 SHOWN,

OTHER SPEC. NOS. SIMILAR
OPTION ACCESS OPENING

MODEM, RS-232, RS-485, OR ETHERNET
(COVER REMOVED)
(note Ethernet port located on side of option)
CIRCUIT CARD
MODEM, RS-232, RS-485, OR ETHERNET OPTION
SUPPLIED OPTION
MOUNTING BRACKET
MCA
SCREW
CIRCUIT
CARD
LOCK
VISIBLE
WASHER
IN OPTION
ACCESS
OPENING
ATTACH SUPPLIED
LABEL(S) HERE
OUTSIDE VIEW OF VPS
INTELLIGENCE SHELF'S MATING
RIGHT SIDE PANEL CONNECTORS
SECURING MODEM, RS-232, RS-485, OR ETHERNET SECURING MODEM, RS-232, RS-485, OR ETHERNET
CIRCUIT CARD TO MOUNTING BRACKET DETAIL OPTION TO VPS INTELLIGENCE SHELF DETAIL
Figure 1-6
Installing the MCA Modem, RS-232, RS-485, or Ethernet Interface Option

MCA CIRCUIT CARD RS-232/MODEM OPTION

VISIBLE IN OPTION
ACCESS OPENING
RIGHT
SIDE
VIEW
MATING
FRONT OF VPS CONNECTORS
INTELLIGENCE
SHELF SECURING RS-232/MODEM OPTION
TO VPS INTELLIGENCE SHELF DETAIL
OTHER SPEC. NOS. SIMILAR OPTION ACCESS OPENING
(COVER REMOVED)
Figure 1-7
Installing the MCA RS-232/Modem Interface Option

INSTALLING SIDE COVER PANELS

Note: Side cover panels must be installed after a VPS Intelligence or Expansion Shelf is
mounted to a relay rack, and after all wiring is complete.
Two side cover panels are furnished with each VPS Intelligence and Expansion Shelf.
These panels attach to the front of the left and right sides of the shelf to extend the sides
flush with the relay rack.
A flat-blade and cross-blade screwdriver is required to install the panels.
Procedure:
Note: Install the panels only after securing the VPS Intelligence or Expansion Shelf
to a relay rack.
Note: Refer to Figure 1-8A or 1-8B as this procedure is performed.
1) Open the VPS Intelligence or Expansion Shelf's front door by turning and holding
2) Place the side cover panel on the side of the shelf, oriented as shown in Figure
1-8A or 1-8B.
3) Align the two (2) mounting holes in the panel with the corresponding mounting
holes provided on the side of the shelf.
4) Secure the panel to the shelf with the screws provided. These screws are
installed from inside the shelf, and screw into holes provided on the panel.
5) Close the VPS Intelligence Shelf's front door. The door can be shut without

SIDE COVER PANEL
TWO (2) 6-32X1/4"

THREAD FORMING
SCREWS INSTALLED
FROM INSIDE THE
SHELF TO SECURE THE
SIDE COVER PANEL
FRONT OF VPS
INTELLIGENCE OR EXPANSION SHELF
(FRONT DOOR REMOVED FOR CLARITY)
SIDE COVER PANEL

TWO (2) 6-32X1/4"
THREAD FORMING
SCREWS INSTALLED
FROM INSIDE THE
SHELF TO SECURE THE
SIDE COVER PANEL
Figure 1-8A
Installing Side Cover Panels
(Spec. Nos. 588700701, 588700801, 588703600, and 588703700)

SIDE
COVER
PANEL
FRONT OF VPS
INTELLIGENCE OR
EXPANSION SHELF
(FRONT DOOR REMOVED
FOR CLARITY)
FOUR (4) 6-32X1/4"

THREAD FORMING
SCREWS INSTALLED SIDE
FROM INSIDE THE COVER
SHELF TO SECURE THE PANEL
SIDE COVER PANEL
Figure 1-8B
Installing Side Cover Panels
(Spec. Nos. 588701300 and 588701400)


CHAPTER 2
SETTING VPS WIRING OPTIONS
Note: A Battery Thermal Runaway Management System may be furnished. For wiring
option information, refer to the Battery Thermal Runaway Management System
instructions (Section 5593), included in this manual.
TABLE OF CONTENTS
Observe the Following Admonishments.......................................................................... 2-2
(Spec. Nos. 588700701, 588700801, 588703600, and 588703700) .............................. 2-3
(Spec. Nos. 588701300 and 588701400) ....................................................................... 2-8
VPS Intelligence Shelf Internal/External Voltage
Sensing Switch (Spec. No. 588701300)........................................................................ 2-12
VPS Intelligence Shelf Internal/External System Voltage
Meter Reading Switch (Spec. No. 588701300) ............................................................. 2-14
VPS Distribution Cabinet Assembly Internal/External Voltage Sensing
and Internal/External System Voltage Meter Reading Circuit Card .............................. 2-17
VPS Distribution Cabinet Assembly Fuses and Fuse Alarm Polarity Circuit Card........ 2-18
VPS Distribution Cabinet Assembly LVD (J5) and Shunt POD (J6) Jumpers .............. 2-19
VPS Distribution Cabinet Assembly Shunt POD Shunt Capacity Selection Switch...... 2-22
VPS Distribution Cabinet Assembly Shunt POD
System/Subsystem Identification Jumper ..................................................................... 2-23
VPS Distribution Cabinet Assembly Low Voltage
Disconnect Circuit Card Identification Switch................................................................ 2-26
MCA Local and Remote Access Lockout Switches ...................................................... 2-29
MCA Modem Interface Option "Number of Rings Before Answer" Jumper .................. 2-32
MCA RS-232/Modem Interface Option "Number of Rings Before Answer" Jumper ..... 2-35
MCA RS-232/Modem Interface Option "RS-232 Port Hardware Handshake" Jumper . 2-37
Lorain® Battery Charge Temperature Compensation
Module Maximum Voltage Clamp Selection.................................................................. 2-40
Chapter 2. Setting VPS Wiring Options Page 2-1

OBSERVE THE FOLLOWING ADMONISHMENTS

Danger: Performing the following procedures may expose service personnel to
hazards. These procedures should be performed by qualified service
personnel familiar with the hazards associated with this type of
equipment. These hazards may include shock, energy, and/or burns. To
avoid these hazards:
a) The tasks should be performed in the order indicated.
b) Remove watches, rings, and other jewelry.
c) Prior to contacting any uninsulated surface or termination, use a

voltmeter to verify that no voltage or the expected voltage is present.
d) Wear eye protection, and use recommended tools.
Page 2-2 Chapter 2. Setting VPS Wiring Options

VPS INTELLIGENCE AND EXPANSION SHELF PCU

MOUNTING POSITIONS IDENTIFICATION SWITCHES
(SPEC. NOS. 588700701, 588700801, 588703600, AND 588703700)
These switches are located within each VPS Intelligence and Expansion Shelf. Two
switches are provided for each PCU mounting position. Refer to Figure 2-1A.
A small flat blade screwdriver is required to change the settings of these switches.
The MCA must be able to uniquely identify each PCU installed in the system. This
identification is done via these switches. Set the switches in all VPS Intelligence and
Expansion Shelves that are a part of the system to a different PCU identification setting,
as described in the following procedure. DO NOT identify two or more PCU mounting
positions with the same switch settings.
Procedure:
2) To access the switches, remove any PCU installed, as detailed in a) and b)

below.
a) On the PCU to be removed, place the Standby/Operate switch to the

"standby" position, then the OUTPUT BREAKER to the 0 "off" position.
Note: The OUTPUT BREAKER has a mechanical interlock which prevents a

PCU from being plugged into or pulled out of a shelf with the circuit
breaker in the "on" position.
b) Loosen the captive fasteners on the front of the PCU to be removed. Use
the handle provided on the front of the PCU, and pull the PCU from the shelf.
Support the bottom of the PCU as you pull it out.
3) Refer to Figure 2-1A, and locate the PCU Mounting Positions Identification
Switches (S1 through S8) on the VPS Intelligence or Expansion Shelf.
4) PCUs are identified by a number from 01 to 56. Each PCU mounting position
has a pair of switches associated to it. The S2/S1 pair identifies the PCU
installed in shelf mounting position #1. The S4/S3 pair identifies the PCU
installed in shelf mounting position #4. The first switch in the pair (and the one
that is physically located first) identifies the first digit of the number. The second
switch in the pair (and the one that is physically located second) identifies the
second digit. Set each pair of switches located within the shelf to a different PCU
identification number. Use the following as an example.
To set the PCU installed in mounting position #1 as PCU #01, set S2 to 0 and S1
to 1. This identifies the PCU as #01.

As another example, ...
To set the PCU installed in mounting position #1 of a fifth shelf that is part of the
system as PCU #17, set S2 to 1 and S1 to 7. This identifies the PCU as #17.
Table 2-1A provides suggested switch settings for up to fourteen VPS

Intelligence and Expansion Shelves. It is suggested that you identify all positions
at this time, even for mounting positions that are not to be immediately used. It is
also suggested that you record the VPS Intelligence or Expansion Shelf number,
PCU mounting position number, and the PCU identification number for each PCU
installed in the system. This record makes it easier if the system ever needs to
be expanded.
5) Reinstall the PCUs, if removed during this procedure, as detailed below.

position.
b) Ensure that the OUTPUT BREAKER on the PCU is in the 0 "OFF" position.
c) Slide the PCU into its mounting position. Secure it to the shelf by tightening
the captive fasteners located on the front panel.
d) If the PCU was operating before this procedure was performed, place the
Standby/Operate switch on this PCU to the I "operate" position, then the
OUTPUT BREAKER to the I "on" position.
6) Verify that all PCU handles are in the down position. Close the VPS Intelligence
or Expansion Shelf's front door. The door can be shut without turning the captive
fastener.
7) If the system consists of other VPS Intelligence or Expansion Shelves, set these
switches on each additional shelf to different PCU identification numbers.

PCU
PCU PCU
Mounting Switch
Identification Shelf
Position Settings
Number Number
Number
#01 #1 #1 S2 to 0, S1 to 1
#02 #1 #2 S4 to 0, S3 to 2
#03 #1 #3 S6 to 0, S5 to 3
#04 #1 #4 S8 to 0, S7 to 4
#05 #2 #1 S2 to 0, S1 to 5
#06 #2 #2 S4 to 0, S3 to 6
#07 #2 #3 S6 to 0, S5 to 7
#08 #2 #4 S8 to 0, S7 to 8
#09 #3 #1 S2 to 0, S1 to 9
#10 #3 #2 S4 to 1, S3 to 0
#11 #3 #3 S6 to 1, S5 to 1
#12 #3 #4 S8 to 1, S7 to 2
#13 #4 #1 S2 to 1, S1 to 3
#14 #4 #2 S4 to 1, S3 to 4
#15 #4 #3 S6 to 1, S5 to 5
#16 #4 #4 S8 to 1, S7 to 6
#17 #5 #1 S2 to 1, S1 to 7
#18 #5 #2 S4 to 1, S3 to 8
#19 #5 #3 S6 to 1, S5 to 9
#20 #5 #4 S8 to 2, S7 to 0
#21 #6 #1 S2 to 2, S1 to 1
#22 #6 #2 S4 to 2, S3 to 2
#23 #6 #3 S6 to 2, S5 to 3
#24 #6 #4 S8 to 2, S7 to 4
#25 #7 #1 S2 to 2, S1 to 5
#26 #7 #2 S4 to 2, S3 to 6
#27 #7 #3 S6 to 2, S5 to 7
#28 #7 #4 S8 to 2, S7 to 8
Table 2-1A (cont'd on next page)
Suggested PCU Identification Switch Settings

PCU
PCU PCU
Mounting Switch
Position Settings
Number Number
Number
#29 #8 #1 S2 to 2, S1 to 9
#30 #8 #2 S4 to 3, S3 to 0
#31 #8 #3 S6 to 3, S5 to 1
#32 #8 #4 S8 to 3, S7 to 2
#33 #9 #1 S2 to 3, S1 to 3
#34 #9 #2 S4 to 3, S3 to 4
#35 #9 #3 S6 to 3, S5 to 5
#36 #9 #4 S8 to 3, S7 to 6
#37 #10 #1 S2 to 3, S1 to 7
#38 #10 #2 S4 to 3, S3 to 8
#39 #10 #3 S6 to 3, S5 to 9
#40 #10 #4 S8 to 4, S7 to 0
#41 #11 #1 S2 to 4, S1 to 1
#42 #11 #2 S4 to 4, S3 to 2
#43 #11 #3 S6 to 4, S5 to 3
#44 #11 #4 S8 to 4, S7 to 4
#45 #12 #1 S2 to 4, S1 to 5
#46 #12 #2 S4 to 4, S3 to 6
#47 #12 #3 S6 to 4, S5 to 7
#48 #12 #4 S8 to 4, S7 to 8
#49 #13 #1 S2 to 4, S1 to 9
#50 #13 #2 S4 to 5, S3 to 0
#51 #13 #3 S6 to 5, S5 to 1
#52 #13 #4 S8 to 5, S7 to 2
#53 #14 #1 S2 to 5, S1 to 3
#54 #14 #2 S4 to 5, S3 to 4
#55 #14 #3 S6 to 5, S5 to 5
#56 #14 #4 S8 to 5, S7 to 6
Table 2-1A (cont'd from previous page)

S2 S1 S4 S3 S6 S5 S8 S7
PCU PCU PCU PCU

MOUNTING MOUNTING MOUNTING MOUNTING
POSITION #1 POSITION #2 POSITION #3 POSITION #4
CABINET TOP
REMOVED
FOR CLARITY
FRONT OF VPS
INTELLIGENCE SHELF
(EXPANSION SHELF SAME
EXCEPT FRONT DOOR AND
SIDE PANEL CONNECTORS)
Figure 2-1A
VPS Intelligence and Expansion Shelf PCU Mounting Positions Identification Switches Location
(Spec. Nos. 588700701, 588700801, 588703600, and 588703700)

VPS INTELLIGENCE AND EXPANSION SHELF PCU

MOUNTING POSITIONS IDENTIFICATION SWITCHES
(SPEC. NOS. 588701300 AND 588701400)
These switches are located within each VPS Intelligence and Expansion Shelf. Two
switches are provided for each PCU mounting position. Refer to Figure 2-1B.
A small flat blade screwdriver is required to change the settings of these switches.
The MCA must be able to uniquely identify each PCU installed in the system. This
identification is done via these switches. Set the switches in all VPS Intelligence and
Expansion Shelves that are a part of the system to a different PCU identification setting,
as described in the following procedure. DO NOT identify two or more PCU mounting
positions with the same switch settings.
Procedure:
2) To access the switches, remove any PCU installed, as detailed in a) and b)

below.

"standby" position, then the Output Breaker to the 0 "off" position.
b) Loosen the captive fasteners secured to the front of all PCUs installed. Pivot
the hinged panel containing the captive fasteners down. Use the handle
provided on the front of the PCU to be removed, and pull the PCU from the
shelf. Support the bottom of the PCU as you pull it out.
3) Refer to Figure 2-1B, and locate the PCU Mounting Positions Identification
Switches (S1 through S8) inside the VPS Intelligence or Expansion Shelf.
4) PCUs are identified by a number from 01 to 20. Each PCU mounting position
has a pair of switches associated to it. The S8/S7 pair identifies the PCU
installed in shelf mounting position #4. The first switch in the pair (and the one
that is physically located first) identifies the first digit of the number. The second
switch in the pair (and the one that is physically located second) identifies the
second digit. Set each pair of switches located within the shelf to a different PCU
identification number. Use the following as an example.

As another example, ...
Table 2-1B provides suggested switch settings for up to five VPS Intelligence and
Expansion Shelves. It is suggested that you identify all positions at this time,
even for mounting positions that are not to be immediately used. It is also
suggested that you record the VPS Intelligence or Expansion Shelf number, PCU
mounting position number, and the PCU identification number for each PCU
installed in the system. This record makes it easier if the system ever needs to
be expanded.

position.
b) Ensure that the Output Breaker on the PCU is in the 0 "OFF" position.
c) Slide the PCU into its mounting position. Pivot the hinged panel containing
the captive fasteners up. For each PCU installed, tighten the respective
captive fastener located on the hinged panel to secure the PCU to the shelf.
Output Breaker to the I "on" position.
6) Close the VPS Intelligence or Expansion Shelf's front door. The door can be
shut without turning the captive fastener.
7) If the system consists of other VPS Intelligence or Expansion Shelves, set these
switches on each additional shelf to different PCU identification numbers.

PCU
PCU PCU
Mounting Switch
Position Settings
Number Number
Number
#01 #1 #1 S8 to 0, S7 to 1
#02 #1 #2 S6 to 0, S5 to 2
#03 #1 #3 S4 to 0, S3 to 3
#04 #1 #4 S2 to 0, S1 to 4
#05 #2 #1 S8 to 0, S7 to 5
#06 #2 #2 S6 to 0, S5 to 6
#07 #2 #3 S4 to 0, S3 to 7
#08 #2 #4 S2 to 0, S1 to 8
#09 #3 #1 S8 to 0, S7 to 9
#10 #3 #2 S6 to 1, S5 to 0
#11 #3 #3 S4 to 1, S3 to 1
#12 #3 #4 S2 to 1, S1 to 2
#13 #4 #1 S8 to 1, S7 to 3
#14 #4 #2 S6 to 1, S5 to 4
#15 #4 #3 S4 to 1, S3 to 5
#16 #4 #4 S2 to 1, S1 to 6
#17 #5 #1 S8 to 1, S7 to 7
#18 #5 #2 S6 to 1, S5 to 8
#19 #5 #3 S4 to 1, S3 to 9
#20 #5 #4 S2 to 2, S1 to 0
Table 2-1B
(Spec. Nos. 588701300 and 588701400)

S8 S7 S6 S5 S4 S3 S2 S1
PCU PCU PCU PCU

MOUNTING MOUNTING MOUNTING MOUNTING
POSITION #1 POSITION #2 POSITION #3 POSITION #4
SECTION OF
CABINET TOP
REMOVED
FOR CLARITY
FRONT OF VPS
INTELLIGENCE SHELF
Figure 2-1B
VPS Intelligence and Expansion Shelf PCU Mounting Positions Identification Switches Location
(Spec. Nos. 588701300 and 588701400)

VPS INTELLIGENCE SHELF

INTERNAL/EXTERNAL VOLTAGE SENSING SWITCH
(SPEC. NO. 588701300)
This switch is located within the VPS Intelligence Shelf. Refer to Figure 2-1C.
The position of this switch determines if the PCUs are sensing output voltage at the VPS
Intelligence Shelf's output bus (internal), or at a location connected to the system via the
external voltage sensing leads (external). A procedure is provided, later in these
instructions, detailing connection of external voltage sensing leads.
IN THIS SYSTEM, SET THIS SWITCH TO THE EXTERNAL POSITION.
Adjust this switch as described in the following procedure.
Procedure:
1) Open the VPS Intelligence Shelf's front door by turning and holding the captive
2) To access the switch, remove the PCU from mounting position #3, if installed, as
detailed in a) and b) below. PCU positions are counted left to right, as viewed
from the front of the shelf.

3) Refer to Figure 2-1C, and locate the Internal/External Voltage Sensing Switch
(S9) inside the VPS Intelligence Shelf.
4) For Internal Voltage Sensing: Place the switch in the INT position. IN THIS
SYSTEM, DO NOT SET THIS SWITCH TO THE "INT" POSITION.
For External Voltage Sensing: Place the switch in the EXT position. IN THIS
SYSTEM, SET THIS SWITCH TO THE "EXT" POSITION.
5) Reinstall the PCU, if removed during this procedure, as detailed below.

position.
b) Ensure that the Output Breaker on the PCU is in the 0 "off" position.


VPS INTELLIGENCE SHELF INTERNAL/EXTERNAL

SYSTEM VOLTAGE METER READING SWITCH
(SPEC. NO. 588701300)
This switch is located within the VPS Intelligence Shelf. Refer to Figure 2-1C.
The position of this switch determines the voltage source the MCA displays as "System
Output Voltage". This can either be the voltage at the VPS Intelligence Shelf's output bus
(internal), or at a remote location connected to the system via the external system voltage
meter reading leads (external). A procedure is provided, later in these instructions,
detailing connection of external system voltage meter reading leads.
IN THIS SYSTEM, SET THIS SWITCH TO THE EXTERNAL POSITION.
Adjust this switch as described in the following procedure.
Procedure:
1) Open the VPS Intelligence Shelf's front door by turning and holding the captive
2) To access the switch, remove the PCU from mounting position #3, if installed, as
detailed in a) and b) below. PCU positions are counted from left to right, as
viewed from the front of the shelf.

3) Refer to Figure 2-1C, and locate the Internal/External System Voltage Meter
Reading Switch (S10) inside the VPS Intelligence Shelf.
4) For Internal System Voltage Meter Reading: Place the switch in the INT
position. IN THIS SYSTEM, DO NOT SET THIS SWITCH TO THE "INT"
POSITION.
For External System Voltage Meter Reading: Place the switch in the EXT
position. IN THIS SYSTEM, SET THIS SWITCH TO THE "EXT" POSITION.

position.


SYSTEM VOLTAGE
SENSE METER READING
SWITCH SWITCH
S9 S10
INT EXT INT EXT

SNS VSYS
SECTION OF
CABINET TOP
REMOVED
FOR CLARITY
FRONT OF VPS
INTELLIGENCE SHELF
Figure 2-1C
VPS Intelligence Shelf Internal/External Voltage Sense Switch (S9) and
VPS Intelligence Shelf Internal/External System Voltage Meter Reading Switch (S10) Locations
(Spec. Nos. 588701300 and 588701400)

VPS DISTRIBUTION CABINET ASSEMBLY

INTERNAL/EXTERNAL VOLTAGE SENSING AND
INTERNAL/EXTERNAL SYSTEM VOLTAGE METER
READING CIRCUIT CARD
This circuit card is located on "Connector Assembly" circuit card 500441 mounted in the
main VPS Distribution Cabinet Assembly (the one connected to the MCA). Refer to
Figure 2-2.
The orientation of this circuit card determines ...
1) If the PCUs are sensing output voltage through internal Vortex Distribution wiring
(internal), or at a location connected to the system via the external voltage
sensing leads (external).
2) If the voltage source the MCA displays as "System Output Voltage" is the voltage
source connected through the internal Vortex Distribution wiring (internal), or the
voltage source connected to the system via the external system voltage meter
reading leads (external).
A procedure is provided, later in these instructions, detailing connection of external

voltage sensing leads.
A procedure is provided, later in these instructions, detailing connection of external

system voltage meter reading leads.
Orient this circuit card as described in the following procedure.
Procedure:
Note: A circuit card 500441 is located in each VPS Distribution Cabinet Assembly.
Perform this procedure only on circuit card 500441 located in the main VPS
Distribution Cabinet Assembly (the one connected to the MCA). The orientation
of circuit card assembly 500476 on circuit card 500441 located in supplemental
distribution cabinets has no effect.
1) Refer to Figure 2-2, and locate "Connector Assembly" circuit card 500441
mounted in the main VPS Distribution Cabinet Assembly (the one connected to
the MCA).
2) Refer to Figure 2-2, and locate the Internal/External Voltage Sensing and
Internal/External System Voltage Meter Reading circuit card (assembly 500476)
installed on "Connector Assembly" circuit card 500441 at J4.
3) For Internal Voltage Sensing and Internal System Voltage Meter Reading:
Orient the circuit card so that the SENSE ARROW points to INT.
For External Voltage Sensing and External System Voltage Meter Reading:
Orient the circuit card so that the SENSE ARROW points to EXT.


FUSES AND FUSE ALARM POLARITY CIRCUIT CARD
This circuit card is located on "Connector Assembly" circuit card 500441 mounted in each
VPS Distribution Cabinet Assembly. Refer to Figure 2-2. The orientation of this circuit
card is factory set. The following procedure is provided to check the factory setting.
The orientation of this circuit card sets the proper polarity for the fuses and fuse alarm
circuits.
Orient this circuit card as described in the following procedure.
Procedure:
Perform this procedure on circuit card 500441 located in each VPS Distribution
Cabinet Assembly.
mounted in each VPS Distribution Cabinet Assembly.
2) Refer to Figure 2-2, and locate the Fuses and Fuse Alarm circuit card (assembly
500477) installed on "Connector Assembly" circuit card 500441 at J7.
3) If System Distribution Voltage is -48V (this assumes subsystem distribution

voltage is +24V): Orient the circuit card so that the SYSTEM ARROW points to
-48V.
If System Distribution Voltage is +24V (this assumes subsystem

distribution voltage is -48V): Orient the circuit card so that the SYSTEM
ARROW points to +24V.
4) If the system consists of other Vortex Distribution Cabinets, set this option as
required on each cabinet.


LVD (J5) AND SHUNT POD (J6) JUMPERS
The following jumpers are provided on "Connector Assembly" circuit card 500441
mounted in each VPS Distribution Cabinet Assembly. Refer to Figure 2-2. These
jumpers are factory set. The following procedures are provided to check the factory
settings.
LVD Jumper (J5) Procedure:
Cabinet Assembly.
2) Refer to Figure 2-2, and locate connector J5 on this circuit card.
3) If the Vortex Distribution Cabinet that contains this circuit card is the last cabinet
containing Low Voltage Disconnect circuit cards, or if the system only consists of
this cabinet and contains Low Voltage Disconnect circuit cards, place the
supplied jumper between pins 1 and 2 of J5. In all other cases, store the
supplied jumper on pins 2 and 3 of J5.
Shunt POD Jumper (J6) Procedure:
Cabinet Assembly.
2) Refer to Figure 2-2, and locate connector J6 on this circuit card.
3) If the Vortex Distribution Cabinet containing this circuit card DOES NOT contain
a Shunt POD and IS interconnected between cabinets containing Shunt POD's,
place the supplied jumper between pins 1 and 2 of J6. In all other cases, store
the supplied jumper on pins 2 and 3 of J6.

A5
LOAD D BUS
A6
A1
LOAD C BUS
A7
A2 LOAD B BUS
LOAD A BUS A8
A3
A9
A4
A10
INSIDE LEFT SIDE FRONT VIEW OF VPS INSIDE RIGHT SIDE

VIEW OF VPS DISTRIBUTION DISTRIBUTION CABINET ASSEMBLY VIEW OF VPS DISTRIBUTION
CABINET ASSEMBLY (NUMBER (DOOR OPEN) CABINET ASSEMBLY (NUMBER
OF CIRCUIT CARDS VARY) (NUMBER OF BUSES VARY) OF CIRCUIT CARDS VARY)
"CONNECTOR ASSEMBLY"
CIRCUIT CARD (500441)
Figure 2-2 (cont'd on next page)

Internal/External Voltage Sensing and Internal/External System Voltage Meter Reading Circuit Card Location
Fuses and Fuse Alarm Polarity Circuit Card Location
LVD and Shunt POD Interface Jumper Location

Last Low
Voltage
Storage No Shunt Storage Disconnect
Position POD Position Position Position
1 1 1 1
2 or 2 2 or 2
3 3 3 3
J6 J6 J5 J5
J6 J5
J7
J4
S S
Y E
S N
T S
E E
M
Internal/External
Voltage Sensing and
Fuses and Fuse Alarm Internal/External
Polarity Circuit Card System Voltage
(500477) Location Meter Reading
Circuit Card (500476)
Location
Figure 2-2 (cont'd from previous page)

Internal/External Voltage Sensing and Internal/External System Voltage Meter Reading Circuit Card Location
Fuses and Fuse Alarm Polarity Circuit Card Location
LVD and Shunt POD Interface Jumper Location

VPS DISTRIBUTION CABINET ASSEMBLY SHUNT

POD SHUNT CAPACITY SELECTION SWITCH
Located on each Shunt POD circuit card 433800164 is a switch. This switch allows the
Shunt POD circuit card to be used with a variety of shunt sizes. This switch is factory set
to match the shunt factory connected to the circuit card. The following procedure is
provided to check the factory setting, or to set the switch on a replacement Shunt POD.
Refer to Figure 2-3 for location.
Procedure:
the captive fastener in a counterclockwise position.
2) Refer to Figure 2-3, and locate a Shunt POD circuit card 433800164 on the
inside of the VPS Distribution Cabinet Assembly's right side panel. Locate
Switch S1 on the circuit card.
3) Refer to Table 2-2, and set this switch to match the capacity of the shunt
connected to this circuit card.
Switch S1 Shunt Capacity Switch S1 Shunt Capacity

Position Position
0 100A 8 1200A
1 200A 9 1600A
2 300A A 2000A
3 400A B 3000A
4 500A C 4000A
5 600A D 5000A
6 800A E 8000A
7 1000A F 10000A
Table 2-2
Shunt POD Circuit Card
Shunt Capacity Selection Switch S1 Settings
4) If the cabinet assembly contains other Shunt POD circuit cards, perform steps 2)
and 3) for these shunt POD's. A Shunt POD (subsystem distribution current
monitoring) may also be mounted to the bottom of the VPS Distribution Cabinet
Assembly.
without turning the captive fastener.
6) If the system consists of other VPS Distribution Cabinet Assemblies, set this
option as required on each Shunt POD contained in the additional cabinet
assemblies.

VPS DISTRIBUTION CABINET ASSEMBLY SHUNT POD

SYSTEM/SUBSYSTEM IDENTIFICATION JUMPER
Located on each Shunt POD circuit card 433800164 is a jumper. The installation or
removal of this jumper determines if the MCA identifies this Shunt POD as monitoring
system or subsystem current. This jumper is factory set. The following procedure is
provided to check the factory setting, or to set the jumper on a replacement Shunt POD.
Refer to Figure 2-3 for location.
Procedure:
the captive fastener in a counterclockwise position.
2) Refer to Figure 2-3, and locate a Shunt POD circuit card 433800164 on the
inside of the VPS Distribution Cabinet Assembly's right side panel. Locate
jumper JP1 on the circuit card.
3) To Identify the Shunt as a System Shunt: Remove the jumper from terminals
1 and 2 of JP1. This jumper may be stored on a single terminal of JP1. Shunt
POD's mounted on the cabinet assembly's right side panel should be identified
as monitoring system shunts.
4) To Identify the Shunt as a Subsystem Shunt: Install the jumper onto terminals
1 and 2 of JP1. The Shunt POD mounted, if installed, on the bottom of the
cabinet assembly should be identified as monitoring a subsystem shunt.
5) If the cabinet assembly contains other Shunt POD circuit cards, perform steps 2)
through 4) for these shunt POD's. A Shunt POD (subsystem distribution current
monitoring) may also be mounted to the bottom of the VPS Distribution Cabinet
Assembly.
option as required on each Shunt POD contained in the additional cabinet
assemblies.

A5
LOAD D BUS
A6
A1
LOAD C BUS
A7
A2 LOAD B BUS
A8
A3 LOAD A BUS
A9
A4
A10

SUBSYSTEM
SHUNT
POD
SYSTEM
SHUNT
POD'S
VPS Distribution Cabinet Assembly Shunt POD System/Subsystem Identification Jumper (JP1) and VPS
Distribution Cabinet Assembly Shunt POD Current Capacity Selection Switch (S1) Locations

JP1 JP1
JUMPER OFF: IDENTIFIES SHUNT JUMPER ON: IDENTIFIES SHUNT

AS A SYSTEM SHUNT AS A SUBSYSTEM
SHUNT
NOTE: JUMPER MAY BE STORED ON
A SINGLE TERMINAL OF JP1
SWITCH S1
SYSTEM
AND JUMPER
SUBSYSTEM JP1
SHUNT
POD'S
SHUNT POD CIRCUIT CARD

(433800164)
VPS Distribution Cabinet Assembly Shunt POD System/Subsystem Identification Jumper (JP1) and VPS
Distribution Cabinet Assembly Shunt POD Current Capacity Selection Switch (S1) Locations

VPS DISTRIBUTION CABINET ASSEMBLY LOW VOLTAGE

DISCONNECT CIRCUIT CARD IDENTIFICATION SWITCH
Located on each Low Voltage Disconnect circuit card 514038 is a switch. This switch is
factory set. The following procedure is provided to check the factory setting, or to set the
switch in a replacement Low Voltage Disconnect circuit card. Refer to Figure 2-4 for
location.
Each Low Voltage Disconnect circuit card installed in the system is identified as circuit #1
(LVD1), #2 (LVD2), and/or #3 (LVD3) (via the DIP switch located on the LVD circuit card).
Low Voltage Disconnect circuit cards may be identified as all one #, separate #'s, or a
combination of #'s. The MCA has three LVD disconnect levels (with separate A and B
side setpoints for each level) and a single global reconnect setpoint. These are LVD1,
LVD2, and LVD3. You use the DIP switch on the LVD circuit card to assign which
disconnect level the circuit card operates at (LVD1, LVD2, or LVD3).
Procedure:
2) Refer to Figure 2-4, and locate a Low Voltage Disconnect circuit card 514038 on
the inside of the VPS Distribution Cabinet Assembly's left side panel. Locate
switch S1.
3) Low Voltage Disconnect circuit cards are identified by a number from 01 to 03

(representing LVD1, LVD2, and LVD3 respectively). Refer to Table 2-3, and set
individual switches of switch S1 to the desired identification number.
Place Switch of S1
To Designate As
1 2
LVD Circuit #1 Off On
LVD Circuit #2 On Off
LVD Circuit #3 On On
Table 2-3
Low Voltage Disconnect Circuit Card
Identification Switch S1 Settings
4) If the system consists of other Low Voltage Disconnect circuit cards, set the
switch on these other circuit cards to a different identification number.
option as required on each Low Voltage Disconnect circuit card contained in the
additional cabinet assemblies.

A5
LOAD D BUS
A6
A1
LOAD C BUS
A7
A2
LOAD B BUS
A8
A3 LOAD A BUS
A9
A4
A10

LOW VOLTAGE DISCONNECT

VPS Distribution Cabinet Assembly Low Voltage Disconnect Circuit Card Identification Switch (S1) Location

SWITCH 1
OF S1
S1
OFF ON
SWITCH 2
OF S1
LOW VOLTAGE DISCONNECT

VPS Distribution Cabinet Assembly Low Voltage Disconnect Circuit Card Identification Switch (S1) Location

MCA LOCAL AND REMOTE ACCESS LOCKOUT SWITCHES

These switches are located on the MCA circuit card, and are accessible behind the
option access cover located on the right side (as viewed from the front) of the VPS
Intelligence Shelf. Refer to Figure 2-5.
The following procedure enables/disables changing VPS

adjustment/configuration/calibration settings via the MCA's Local Interface Pad (locally)
or via the MCA's remote interface port(s) (remotely).
Set the switches per site requirements.
Procedure:
1) To access the switches, remove the option access cover (if installed) from the
right side of the VPS Intelligence Shelf by loosening the two captive fasteners.
If a Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option is installed,

remove this option by loosening the two captive fasteners and lifting the option
up and out of the option access opening.
2) Refer to Figure 2-5, and locate switch S1 visible in the option access opening.
a) To disable changing VPS settings locally, place switch 2 of S1 in the ON

position.
To enable changing VPS settings locally, place switch 2 of S1 in the OFF

position.
b) To disable changing VPS settings remotely, place switch 3 of S1 in the ON

position.
To enable changing VPS settings remotely, place switch 3 of S1 in the OFF

position.
3) Replace the option access cover and secure by tightening the captive fasteners,
or replace the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option as
described next.
a) Open the VPS Intelligence Shelf's front door by turning and holding the
captive fastener in the counterclockwise position.
b) The Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option attaches

to the MCA circuit card visible through the option access opening. The
Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option attaches to the
MCA circuit card via a connector that plugs into a mating connector
containing a set of pins on the MCA circuit card. Locate these mating
connectors on the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet
option and the MCA circuit card.
c) Hold the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option by

the edges of the mounting bracket. Orient this option over the option access
opening with the MCA mating connector at the bottom.

d) Push the option into the option access opening, aligning the mating
connectors on the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet
circuit card and the MCA circuit card. You can observe the mating
connectors by looking through the front of the VPS Intelligence Shelf. Push
the Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option in and
down, ensuring the mating connectors are properly aligned. You may need
to push on the metal plate mounting the MCA circuit card from the inside of
the VPS Intelligence Shelf to align the mating connectors. Secure the
Modem, RS-232, RS-232/Modem, RS-485, or Ethernet option to the VPS
Intelligence Shelf by tightening the two captive fasteners located on the
mounting bracket.
e) Close the VPS Intelligence Shelf's front door. The door can be shut without

FRONT OF VPS
INTELLIGENCE SHELF

OPTION ACCESS OPENING
(OPTION COVER, MODEM, RS-232,
S1 RS-232/MODEM, RS-485, OR
ETHERNET OPTION REMOVED)
SWITCH 1 OF S1
1 (UNDEFINED)
SWITCH 2 OF S1
2 LOCAL ACCESS
OFF=ENABLED ON=DISABLED
SWITCH 3 OF S1
3 REMOTE ACCESS
OFF=ENABLED ON=DISABLED MCA
CIRCUIT
4 SWITCH 4 OF S1 CARD
(UNDEFINED)
OFF ON
S1
Figure 2-5
MCA Remote and Local Access Adjustment/Configuration/Calibration Lockout Switches Location

MCA MODEM INTERFACE OPTION

"NUMBER OF RINGS BEFORE ANSWER" JUMPER
This jumper is located on the Modem circuit card (if furnished). This circuit card is
located on the side of the Intelligence Shelf. Refer to Figure 2-6 for jumper location.
The placement of this jumper determines the number of rings before the modem answers
an incoming telephone call.
Set this jumper per site requirements.
Procedure:
1) Connect an approved grounding strap to your wrist. Attach the other end to a
suitable ground.
2) To access the jumper, remove the Modem option from the right side of the VPS
Intelligence Shelf by loosening the two captive fasteners and lifting the modem
option up and out of the option access opening.
3) Remove the Modem circuit card from its mounting bracket.
4) Refer to Figure 2-6, and locate J3 on the Modem circuit card.
a) To set the modem to answer on 1 ring, remove the jumper from the two pins
of J3. The jumper may be stored on one of the pins. This is the factory
setting.
b) To set the modem to answer on 5 rings, place the jumper provided on the
two pins of J3.
Note: When the MCA modem is set to answer on 5 rings, add the following
to the end of the modem initialization string set in Vortex WinLink:
S7=60.
5) Resecure the Modem circuit card to its mounting bracket.
6) Replace the Modem option as described next.
b) The Modem option attaches to the MCA circuit card visible through the option
access opening. The Modem option attaches to the MCA circuit card via a
connector that plugs into a mating connector containing a set of pins on the
MCA circuit card. Locate these mating connectors on the Modem option and
the MCA circuit card.
c) Hold the Modem option by the edges of the mounting bracket. Orient this
option over the option access opening with the MCA mating connector at the
bottom.

connectors on the Modem circuit card and the MCA circuit card. You can
observe the mating connectors by looking through the front of the VPS
Intelligence Shelf. Push the Modem option in and down, ensuring the mating
connectors are properly aligned. You may need to push on the metal plate
mounting the MCA circuit card from the inside of the VPS Intelligence Shelf
to align the mating connectors. Secure the Modem or option to the VPS
Intelligence Shelf by tightening the two captive fasteners located on the
mounting bracket.
7) Remove the grounding wrist strap.

FRONT OF VPS
INTELLIGENCE SHELF

Modem Circuit Card 486781300
MODEM
CIRCUIT CARD
SUPPLIED OPTION
MOUNTING BRACKET
J3, "Number
of Rings Before
Answer" Jumper
SCREW
LOCK
WASHER
Figure 2-6
Modem Circuit Card "Number of Rings before Answer" Jumper Location

MCA RS-232/MODEM INTERFACE OPTION

"NUMBER OF RINGS BEFORE ANSWER" JUMPER
This jumper is located on the RS-232/Modem assembly (if furnished). This assembly is
The placement of this jumper determines the number of rings before the modem answers
an incoming telephone call.
Set this jumper per site requirements.
Procedure:
suitable ground.
2) To access the jumper, remove the RS-232/Modem option from the right side of
the VPS Intelligence Shelf by loosening the two captive fasteners and lifting the
RS-232/Modem option up and out of the option access opening.
3) Remove the RS-232/Modem assembly from its mounting bracket.
4) Refer to Figure 2-7, and locate J3 on the RS-232/Modem assembly.
a) To set the modem to answer on 1 ring, remove the jumper from the pins 1
and 2 of J3. The jumper may be stored on one of the pins.
To set the modem to answer on 5 rings, place the jumper provided between
pins 1 and 2 of J3.
Note: When the MCA modem is set to answer on 5 rings, add the following
to the end of the modem initialization string set in Vortex WinLink:
S7=60.
5) Resecure the RS-232/Modem assembly to its mounting bracket.
6) Replace the RS-232/Modem option as described next.
b) The RS-232/Modem option attaches to the MCA circuit card visible through
the option access opening. The RS-232/Modem option attaches to the MCA
circuit card via a connector that plugs into a mating connector containing a
RS-232/Modem option and the MCA circuit card.
c) Hold the RS-232/Modem option by the edges of the mounting bracket.

Orient this option over the option access opening with the MCA mating
connector at the bottom.

connectors on the RS-232/Modem assembly and the MCA circuit card. You
can observe the mating connectors by looking through the front of the VPS
Intelligence Shelf. Push the RS-232/Modem option in and down, ensuring
the mating connectors are properly aligned. You may need to push on the
metal plate mounting the MCA circuit card from the inside of the VPS
Intelligence Shelf to align the mating connectors. Secure the RS-232/Modem
option to the VPS Intelligence Shelf by tightening the two captive fasteners
located on the mounting bracket.

MCA RS-232/MODEM INTERFACE OPTION

"RS-232 PORT HARDWARE HANDSHAKE" JUMPER
This jumper is located on the RS-232/Modem assembly (if furnished). This assembly is
The placement of this jumper determines if the RS-232 Port Hardware Handshaking is
enabled or disabled.
Set this jumper per site requirements. Note for use with Vortex WinLink, Hardware
Handshaking is not required.
Procedure:
suitable ground.
2) To access the jumper, remove the RS-232/Modem option from the right side of
the VPS Intelligence Shelf by loosening the two captive fasteners and lifting the
RS-232/Modem option up and out of the option access opening.
3) Remove the RS-232/Modem assembly from its mounting bracket.
4) Refer to Figure 2-7, and locate J3 on the RS-232/Modem assembly.
a) To enable Hardware Handshaking, remove the jumper from the pins 3 and 4
of J3. The jumper may be stored on one of the pins.
To disable Hardware Handshaking, place the jumper provided between pins

3 and 4 of J3.
5) Resecure the RS-232/Modem assembly to its mounting bracket.
6) Replace the RS-232/Modem option as described next.
b) The RS-232/Modem option attaches to the MCA circuit card visible through
the option access opening. The RS-232/Modem option attaches to the MCA
circuit card via a connector that plugs into a mating connector containing a
RS-232/Modem option and the MCA circuit card.
c) Hold the RS-232/Modem option by the edges of the mounting bracket.

Orient this option over the option access opening with the MCA mating
connector at the bottom.
connectors on the RS-232/Modem assembly and the MCA circuit card. You
can observe the mating connectors by looking through the front of the VPS

Intelligence Shelf. Push the RS-232/Modem option in and down, ensuring

the mating connectors are properly aligned. You may need to push on the
metal plate mounting the MCA circuit card from the inside of the VPS
Intelligence Shelf to align the mating connectors. Secure the RS-232/Modem
option to the VPS Intelligence Shelf by tightening the two captive fasteners
located on the mounting bracket.

SCREWS
RS-232/MODEM
CIRCUIT CARD
MOUNTING
BRACKET
SHELF SIDE COVER

DRESS PANEL
1
6
Jumper OFF:
RTS/CTS 9
5
Hardware
J3 Pins 3 and 4 Handshake
RS-232 Port
Hardware Jumper ON:
Handshake NO
Hardware 4
Handshake 3 RS-232/Modem
2 Assembly
1
Jumper OFF:
One (1)
J3 Pins 1 and 2 J3
Ring
Modem Port
Number of Rings
Jumper ON:
before Answer
Five (5)
Rings
Figure 2-7
RS-232/Modem Assembly, if installed
"Modem Number of Rings Before Answering" and
"RS-232 Port Hardware Handshake" Jumper Locations

LORAIN® BATTERY CHARGE TEMPERATURE COMPENSATION

MODULE MAXIMUM VOLTAGE CLAMP SELECTION
Note: Battery Charge Temperature Compensation Module Part No. 433867000 cannot
be used in systems with more than 20 PCUs .
If a battery charge temperature compensation module is not used with this system, skip
this procedure.
The battery charge temperature compensation module is designed to clamp system

output voltage to one of four available limits. Three of these limits are selected by
installing a jumper wire between terminals located on the terminal assembly connected to
the module. Use a short length of 22 Ga. wire for the jumper. The fourth limit is selected
by not installing (or removing) the jumper.
Electrical connections to the battery charge temperature compensation module are made
via a terminal assembly that is factory connected to the module. This terminal assembly
should not be removed from the module. Wires are connected to terminals on this
assembly using customer-furnished insulated 1/4” right-angle push-on connectors (Part
No. 245366900 or equivalent). These connectors accept a wire size in the range of 22-
18 Ga. Recommended wire size is 22 Ga. Use a hand crimping tool (AMP Part. No.
58078-3 with Die No. 90390-3, or equivalent) to install a connector onto a wire. Following
the instructions provided with the crimp tool or connectors.
Select the desired maximum voltage clamp as described in the following procedure.
Refer to Figure 2-8 for jumper locations.
Note: Use the specified insulated right-angle (flag-type) connectors to allow clearance
between the wiring and the plastic terminal shield.
Procedure:
1) Remove the terminal shield from the terminal assembly by removing the two
screws securing it.
2) For a Maximum System Output Voltage of 56.0 VDC: Connect a jumper

between terminal TB1 (COM) and terminal TB4 (56V).
For a Maximum System Output Voltage of 56.5 VDC: Connect a jumper

between terminal TB1 (COM) and terminal TB3 (56.5V).
For a Maximum System Output Voltage of 57.0 VDC: Connect a jumper

between terminal TB1 (COM) and terminal TB2 (57V).
For a Maximum System Output Voltage of 58.0 VDC: Do not install a jumper.
3) Secure the terminal shield to the terminal assembly, using the screws removed in
step 1). Refer to Figure 2-8 for installation details.

(56V) (56.5V) (57V) (COM)
BATTERY CHARGE TEMPERATURE COMPENSATION MODULE

MAXIMUM VOLTAGE CLAMP JUMPER DETAIL
BATTERY CHARGE TEMPERATURE COMPENSATION MODULE

TERMINAL SHIELD INSTALLATION DETAIL
Figure 2-8
Battery Charge Temperature Compensation Module


CHAPTER 3
MAKING ELECTRICAL CONNECTIONS
Note: A Battery Thermal Runaway Management System may be furnished. For
electrical connection information, refer to the Battery Thermal Runaway
Management System instructions (Section 5593), provided in this manual.
TABLE OF CONTENTS
Observe the Following Admonishment............................................................................ 3-3
Wiring Considerations ..................................................................................................... 3-3
Relay Rack Grounding Connection (Frame Ground) ...................................................... 3-4
AC Input Grounding Connection
Spec. Nos. 588700701, 588700801, 588703600, and 588703700] ............................... 3-5
(Lists 1, 10, and 11 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Individual (4) AC Input Branch Circuits)
[to VPS Intelligence and Expansion Shelf(s)]................................................................ 3-10
(List 15 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - AC Input Line Cords)
(List 8 of Spec. Nos. 588700701 and 588700801 -
Single AC Input Branch Circuit)
(List 14 of Spec. Nos. 588700701, 588700801,
588703600, and 588703700 - Dual AC Input Branch Circuits)
AC Input Grounding Connections
Spec. Nos. 588701300 and 588701400]....................................................................... 3-21
(Individual (4) AC Input Branch Circuits)
[to VPS Intelligence and Expansion Shelves
Spec. Nos. 588701300 and 588701400]....................................................................... 3-23
Shelf(s) Spec. Nos. 588700701, 588700801, 588703600, and 588703700,
and VPS Distribution Cabinet Assembly] ...................................................................... 3-25
Shelf(s) Spec. Nos. 588701300 and 588701400,
and VPS Distribution Cabinet Assembly] ...................................................................... 3-26
[to VPS Intelligence Shelf and VPS Distribution Cabinet Assembly] ............................ 3-29
TXM (Multiple Probe Concentrator Module) Connection (if required) .................... 3-30
Chapter 3. Making Electrical Connections Page 3-1

Quick Connect Guide.............................................................................................. 3-31

500441 (located inside the main VPS Distribution Cabinet Assembly) (all Lists)... 3-46
Connections to J8 on VPS Intelligence Shelf ......................................................... 3-52
Circuit Card 423356900 Procedure (582120100 Lists 40 and 41 only):................. 3-77
Circuit Card 423356100 Procedure (582120100 Lists 40 and 41 only):................. 3-80
Interconnections between Multiple VPS PCU Shelves Located in the Same Rack...... 3-83
Interconnections between Multiple VPS PCU Shelves Located in Separate Racks..... 3-85
Cable Connection(s) to the MCA Interface Option........................................................ 3-87
(if Modem or RS-232/Modem Interface Option furnished)...................................... 3-87
(if RS-485 Interface Option furnished) .................................................................... 3-89
(if RS-232 or RS-232/Modem Interface Option furnished) ..................................... 3-94
(if Ethernet Interface Option furnished)................................................................... 3-96
VPS Intelligence Shelf and VPS Distribution Cabinet Assembly .................................. 3-96
Multiple VPS Distribution Cabinet Assemblies .............................................................. 3-97
Load Connections [to VPS Distribution Cabinet Assembly(s)]...................................... 3-99
Shunt Connections to GJ/218-Type Circuit Breakers E/W Internal Shunt ........... 3-100
Battery Connections [to VPS Distribution Cabinet Assembly(s)] ................................ 3-110
Page 3-2 Chapter 3. Making Electrical Connections

OBSERVE THE FOLLOWING ADMONISHMENT

Danger: Servicing personnel must follow approved safety procedures. This
system operates from AC voltage capable of producing fatal electrical
shock. AC input power must be completely disconnected from the
branch circuits wiring used to provide power to the system before any
electrical connections are made. This system may also require battery to
be connected. Although battery voltage is not hazardously high, the
battery can deliver large amounts of current. Exercise extreme caution
not to inadvertently contact or have any tool inadvertently contact a
battery terminal or exposed wire connected to a battery terminal. Remove
watches, rings, or other jewelry before connecting battery leads.
WIRING CONSIDERATIONS
All wiring and branch circuit protection should follow the current edition of the American
National Standards Institute (ANSI) approved National Fire Protection Association's
(NPFA) National Electrical Code (NEC), and applicable local codes. For operation in
countries where the NEC is not recognized, follow applicable codes.
Refer to the System Application Guide (SAG) and Power Data Sheets (PD) for general
wiring and fusing recommendations. These can be accessed from the CD (Electronic
Documentation Package) provided with your system.

RELAY RACK GROUNDING CONNECTION (FRAME GROUND)

For relay rack grounding requirements, refer to the National Electrical Code, applicable
local codes, and your specific site requirements.
Two 1/4-20 captive nuts or studs on 5/8 inch centers are provided on top of the relay rack
for connection into a customer's grounding network.
When using 1/4 inch hardware, recommended torque is 84 in-lbs when a standard flat
washer and lock washer are used.

AC INPUT GROUNDING CONNECTION

[TO VPS INTELLIGENCE AND EXPANSION SHELF(S)
SPEC. NOS. 588700701, 588700801, 588703600, AND 588703700]
A grounding conductor(s) must be provided with the AC input conductors supplied to
each VPS Intelligence and Expansion Shelf.
Studs (10-32 X 1/2") and hardware are provided in the AC Input Housing Assembly to
attach the grounding conductor(s) to the shelf. Refer to Figures 3-1A, 3-1B, 3-1C, or
3-1D for location. The grounding conductor(s) is to be terminated in a ring lug.
Recommended torque is 23 in-lbs.
Connect to earth ground, not power system neutral.
Refer to the appropriate System Application Guide (SAG) or Power Data Sheet (PD) for
recommended wire size. These can be accessed from the CD (Electronic

FRAME GROUND CONNECTIONS

LOCATED ON INSIDE OF AC INPUT HOUSING
ASSEMBLY
FOUR 10-32 X 1/2" STUDS AND HARDWARE
PROVIDED ON INSIDE OF AC INPUT HOUSING
ASSEMBLY
POSITIVE
OUTPUT
DC OUTPUT
BUSBAR
POWER INTERCONNECTION TO VPS
DISTRIBUTION CABINET ASSEMBLY.
MATING BUSBARS PROVIDED FOR USE REMOVE SCREW TO
WITH A VPS DISTRIBUTION CABINET ASSEMBLY. REMOVE COVER TO
(SEE DETAIL A WHEN NOT USED WITH A VPS GAIN ACCESS TO AC
DISTRIBUTION CABINET) INPUT TERMINAL
BLOCK
SEE DETAIL A
NEGATIVE
OUTPUT
BUSBAR
REAR OF VPS
INTELLIGENCE SHELF
(EXPANSION SHELF SIMILAR)
LISTS 1, 10, and 11 -

Individual AC Input Branch Circuits
AC INPUT CONNECTIONS
8 8 AC INPUT FOR
AC IN
PCU POSITION
REMOVE THE SHORT TOP PCU 4
7 7 #4 CONNECTIONS
BUS BEFORE INSTALLING LUGS
POSITIVE 6 6 AC INPUT FOR
AC IN
OUTPUT BUSBAR PCU POSITION
PCU 3
1.500 5 5 #3 CONNECTIONS
NEGATIVE
OUTPUT BUSBAR 4 4 AC INPUT FOR
AC IN
PCU POSITION
3/8-16 CAPTIVE FASTENER FOR 1.000 PCU 2
#2 CONNECTIONS
3 3
CUSTOMER PROVIDED LUG
MTG. BOLTS (4) PLACES 2 2 AC INPUT FOR
AC IN
PCU POSITION
DETAIL A PCU 1
#1 CONNECTIONS
1 1
DC OUTPUT BUSBAR HOLE SIZE AND SPACING FOR
TB1
INSTALLATION OF CUSTOMER PROVIDED LUGS WHEN
NOT USED WITH A VPS DISTRIBUTION CABINET ASSEMBLY
Figure 3-1A
Frame Ground, AC Input (588700701/588700801 and
588703600/588703700 Lists 1, 10, and 11), and DC Output Connections

FRAME GROUND CONNECTION

ASSEMBLY
POSITIVE ONE 10-32 X 1/2" STUD AND HARDWARE
OUTPUT PROVIDED ON INSIDE OF AC INPUT HOUSING
BUSBAR ASSEMBLY
DC OUTPUT
POWER INTERCONNECTION TO
VORTEX DISTRIBUTION. REMOVE SCREW TO
MATING BUSBARS PROVIDED FOR USE REMOVE COVER TO
WITH A VPS DISTRIBUTION CABINET ASSEMBLY. GAIN ACCESS TO AC
(SEE DETAIL A WHEN NOT USED WITH A VPS INPUT TERMINAL
DISTRIBUTION CABINET) BLOCK
SEE DETAIL A
NEGATIVE
OUTPUT
BUSBAR
REAR OF VPS
INTELLIGENCE SHELF
LIST 8
Single AC Input Branch Circuit
FOR ALL PCU POSITIONS
REMOVE THE SHORT TOP
BUS BEFORE INSTALLING LUGS 1 TB2 2 1/4-20 CAPTIVE
POSITIVE FASTENER, (4) PLACES.
OUTPUT BUSBAR USE SUPPLIED BOLTS
1.500 0.625 AND HARDWARE. DO
NEGATIVE
NOT USE BOLTS
OUTPUT BUSBAR
LONGER THAN THE
3/8-16 CAPTIVE FASTENER FOR 1.000 SUPPLIED BOLTS.
MTG. BOLTS (4) PLACES
DETAIL A
DC OUTPUT BUSBAR HOLE SIZE AND SPACING FOR
NOT USED WITH A VPS DISTRIBUTION CABINET ASSEMBLY 1.125
Figure 3-1B
Frame Ground, AC Input (588700701/588700801 List 8), and DC Output Connections

FRAME GROUND CONNECTION

ASSEMBLY
ONE 10-32 X 1/2" STUD AND HARDWARE
POSITIVE PROVIDED ON INSIDE OF AC INPUT HOUSING
OUTPUT ASSEMBLY
BUSBAR DC OUTPUT
POWER INTERCONNECTION TO REMOVE SCREW TO
VORTEX DISTRIBUTION. REMOVE COVER TO
MATING BUSBARS PROVIDED FOR USE GAIN ACCESS TO
WITH A VPS DISTRIBUTION CABINET ASSEMBLY. AC INPUT TERMINAL
(SEE DETAIL A WHEN NOT USED WITH A VPS BLOCK (TB1)
DISTRIBUTION CABINET)
SEE DETAIL A
NEGATIVE
OUTPUT
BUSBAR
REAR OF VPS
INTELLIGENCE SHELF
LIST 14 - Dual AC Input Branch Circuit
1/4-20 CAPTIVE FASTENER,

REMOVE THE SHORT TOP
(8) PLACES. USE SUPPLIED
BUS BEFORE INSTALLING LUGS BOLTS AND HARDWARE.
POSITIVE DO NOT USE BOLTS LONGER
OUTPUT BUSBAR THAN THE SUPPLIED BOLTS.
1.500
NEGATIVE
OUTPUT BUSBAR
3/8-16 CAPTIVE FASTENER FOR 1.000 2
MTG. BOLTS (4) PLACES TB3 1.125
1
AC INPUT
CONNECTIONS
DETAIL A 2
DC OUTPUT BUSBAR HOLE SIZE AND SPACING FOR TB2 1.125
NOT USED WITH A VPS DISTRIBUTION CABINET ASSEMBLY 1
0.625
Figure 3-1C
Frame Ground, AC Input (588700701/588700801 and
588703600/588703700 List 14), and DC Output Connections

FRAME GROUND
4 10-32 X 1/2" STUDS
AND HARDWARE PROVIDED
ATTACH EACH CORDS FRAME
GROUND WIRE TO STUD NEAREST
PART NO. EACH CORDS ENTRY POINT.
104821
PART NO.
104836
PART NO.
104837
1 2 3 4 5 6 7 8
PART NO.
104838
FRAME X
GROUND
Figure 3-1D
Frame Ground and AC Input (588700701/588700801 and 588703600/588703700 List 15)

(LISTS 1, 10, AND 11 OF SPEC. NOS. 588700701, 588700801,
588703600, AND 588703700 - INDIVIDUAL (4) AC INPUT BRANCH
CIRCUITS) [TO VPS INTELLIGENCE AND EXPANSION SHELF(S)]
588700701, 588700801, 588703600, and 588703700 Lists 1, 10, and 11 provide AC
input connections for each PCU. If using optional List 15 AC Input line cords, refer to
next section "AC INPUT CONNECTIONS (LIST 15) AC INPUT LINE CORDS".
AC input conductors are to be provided for each individual PCU mounting position in
each VPS Intelligence and Expansion Shelf, including currently unused positions. This
wiring will ease future installation of PCUs to meet increased load requirements. These
conductors are connected to terminal block TB1, located within the VPS Intelligence and
Expansion Shelf, as described below.
Refer to Figure 3-1A for terminal block location and identification.
Terminal block TB1 accepts a wire size in the range of 20 to 6 AWG. Recommended
torque is 10.62 to 13.30 in-lbs.
recommended wire size and branch circuit protection (for each PCU position). These can
be accessed from the CD (Electronic Documentation Package) provided with your
system.
Procedure:
2) To access terminal block TB1, remove the PCU from mounting position #1, if
installed, as detailed in a) and b) below. This is the left most position as viewed


3) Terminal block TB1 is located under an access cover now visible under PCU
mounting position #1. Remove the screw on the front of the access cover, and
remove the cover.
4) Connect AC input conductors for PCU mounting position #1 to terminals 1 and 2

of TB1. For 208-240 Volt AC Input Voltage Derived from a Line to Line
System: Connect Line 1 to the terminal designated 1 and Line 2 to the terminal
designated 2. For 208-240 Volt AC Input Voltage Derived from a Line to

Neutral System: Connect Line to the terminal designated 1 and Neutral to the
terminal designated 2.



8) Replace the access cover, and secure with the screw removed.
9) After the AC input and frame ground connections are made to the shelf, place the
Shield provided with the AC Input Housing onto the two (2) upper captive
fasteners on the AC Input Housing. Refer to Figure 1-5A for a diagram. Place
the shield between the cabinet and the wiring (to prevent wires from protruding
into cabinet's rectangular opening).

position.
b) Ensure that the OUTPUT BREAKER on the PCU is in the 0 "off" position.
fastener.
12) Place the AC Input Housing Cover onto the AC Input Housing Base. The cover
fits inside the base. First insert the tab side of the cover into the base. Align the
tabs on the cover into the corresponding openings on the base. Push the right
side of the cover in and to the right until the tabs protrude outside the openings in
the base. Push the left side of the cover in until the captive fasteners on the
cover align with the holes on the base. Secure the cover to the base with the
captive fasteners. Refer to Figure 1-5A for a diagram.

588703700 - AC INPUT LINE CORDS) [TO VPS INTELLIGENCE
AND EXPANSION SHELF(S)]
Note: The factory supplied AC Line Cords must be connected after a VPS Intelligence
or Expansion Shelf is mounted to a relay rack.
588700701, 588700801, 588703600, and 588703700 List 15 provides one AC Line cord
for each PCU and is installed on a 588700701, 588700801, 588703600, and 588703700
List 1, 10, or 11 Shelf.
AC input line cords are provided for each individual PCU mounting position in each VPS
Intelligence and Expansion Shelf, including currently unused positions. This wiring will
ease future installation of PCUs to meet increased load requirements. These cords are
connected to terminal block TB1, located within the VPS Intelligence and Expansion
Shelf, as described below with the customer supplying the mating receptacle to the
supplied 30 Amp Twist-lock (NEMA L6-30P) plug.
Refer to Figure 3-1D for terminal block location and identification.
Terminal block TB1 accepts a wire size in the range of 20 to 6 AWG. Recommended
torque is 10.62 to 13.30 in-lbs.
system.
Procedure:


remove the cover.

4) Remove the four AC line cords from the package. Remove the fitting nut from
each cord. They will be installed in the following steps. Refer to Figure 3-1D for
terminal block location and identification.
5) Insert AC line cord Part No. 104838 (labeled 1 and 2) through the lowermost hole
in the AC Input Housing Base. Install the nut on the fitting. Connect the wire
labeled #1 to terminal 1 of TB1 and connect the wire labeled #2 to terminal 2 of
TB1. Connect the green ground wire to the lowermost ground stud.
For 208-240 Volt AC Input Voltage Derived from a Line to Line System:
Connect Line 1 to the terminal designated Y and Line 2 to the terminal
designated X.
For 208-240 Volt AC Input Voltage Derived from a Line to Neutral System:
Connect Line to the terminal designated Y and Neutral to the terminal
designated X.
6) Insert AC line cord Part No. 104837 (labeled 3 and 4) through the next lowermost
hole in the AC Input Housing Base. Install the nut on the fitting. Connect the
wire labeled #3 to terminal 3 of TB1 and connect the wire labeled #4 to terminal 4
of TB1. Connect the green ground wire to the next lowermost ground stud.
designated X.
Connect Line to the terminal designated Y and Neutral to the terminal
designated X.
7) Insert AC line cord Part No. 104836 (labeled 5 and 6) through the next lowermost
of TB1. Connect the green ground wire to the next lowermost ground stud.
designated X.
Connect Line to the terminal designated Y and Neutral to the terminal designated
X.
8) Insert AC line cord Part No. 104821 (labeled 7 and 8) through the remaining
of TB1. Connect the green ground wire to the remaining ground stud.
designated X.
Connect Line to the terminal designated Y and Neutral to the terminal designated
X.

9) Form the wires in the AC Input Housing for best fit. Tighten the four fitting nuts
and tighten the 4 fitting clamps.
10) After the AC input and frame ground connections are made to the shelf, place the
Shield provided with the AC Input Housing onto the two (2) upper captive
fasteners on the AC Input Housing. Refer to Figure 1-5A for a diagram. Place
the shield between the cabinet and the wiring (to prevent wires from protruding
into cabinet's rectangular opening).
11) Place the AC Input Housing Cover onto the AC Input Housing Base. The cover
captive fasteners. Refer to Figure 1-5A for a diagram.

position.
fastener.

(LIST 8 OF SPEC. NOS. 588700701 AND 588700801 - SINGLE AC
INPUT BRANCH CIRCUIT) [TO VPS INTELLIGENCE AND
EXPANSION SHELF(S)]
588700701 and 588700801 List 8 provides connections for a single shelf AC input branch
circuit which is internally bused to all PCUs in the shelf.
AC input conductors are to be provided for each VPS Intelligence and Expansion Shelf.
These conductors are connected (via customer provided lugs) to the AC input busbars
(TB2) located in the AC Input Housing Assembly of each VPS Intelligence and Expansion
Shelf, as described below.
Refer to Figure 3-1B for busbar location and identification, and busbar lug mounting hole
size and dimensions.
recommended wire size, branch circuit protection, crimp lugs, and torque value. These
can be accessed from the CD (Electronic Documentation Package) provided with your
system.
Attaching the Wires of the AC Input Housing Assembly Procedure: This procedure
may have been factory performed for you. Refer also to the procedure which follows.
The wires supplied with the AC Input Housing Assembly are attached to terminal block
TB2 on the assembly and TB1 located within the VPS Intelligence and Expansion Shelf,
as described below.


remove the cover.
4) Attach the wires supplied with the AC Input Housing Assembly to TB2 on the
assembly as follows:

a) Connect the wires labeled |1|, |3|, |5|, and |7| to terminal 1 of TB2. Torque to
31 in-lbs.
b) Connect the wires labeled |2|, |4|, |6|, and |8| to terminal 2 of TB2. Torque to
31 in-lbs.
VPS PCU Shelf as follows. Recommended torque is 10.62 to 13.30 in-lbs.
a) Connect the wire labeled |1| to terminal 1 of TB1.
b) Connect the wire labeled |2| to terminal 2 of TB1.
c) Connect the wire labeled |3| to terminal 3 of TB1.
d) Connect the wire labeled |4| to terminal 4 of TB1.
e) Connect the wire labeled |5| to terminal 5 of TB1.
f) Connect the wire labeled |6| to terminal 6 of TB1.
g) Connect the wire labeled |7| to terminal 7 of TB1.
h) Connect the wire labeled |8| to terminal 8 of TB1.

position.
fastener.
9) Refer to the procedure which follows for AC input wiring.
Making AC Input Wiring Connections Procedure:
1) Connect AC input lugs and conductors for all PCU mounting positions to the
busbars (TB2) located inside the AC Input Housing Assembly. Use the supplied
bolts and hardware. DO NOT use bolts longer than the supplied bolts. For 208-
240 Volt AC Input Voltage Derived from a Line to Line System: Connect Line
1 to the busbar designated TB2-1 and Line 2 to the busbar designated TB2-2.
Connect Line to the busbar designated TB2-1 and Neutral to the busbar
designated TB2-2. Recommended torque is 50 in-lbs.

2) After the AC input and frame ground connections have been made to the shelf,
place the AC Input Housing Cover onto the AC Input Housing Base. The cover
captive fasteners. Refer to Figure 1-5B for a diagram.

588703700 - DUAL AC INPUT BRANCH CIRCUITS) [TO VPS
INTELLIGENCE AND EXPANSION SHELF(S)]
588700701, 588700801, 588703600, and 588703700 List 14 provides connections for
dual shelf AC input branch circuits which are internally bused to all PCUs in the shelf.
TB2 connects to PCU 1 and PCU3. TB3 connects to PCU 2 and PCU 4.
AC input conductors are to be provided for each VPS Intelligence and Expansion Shelf.
These conductors are connected (via customer provided lugs) to the AC input busbars
(TB2 and TB3) located in the AC Input Housing Assembly of each VPS Intelligence and
Refer to Figure 3-1C for busbar location and identification, and busbar lug mounting hole
size and dimensions.
recommended wire size, branch circuit protection, crimp lugs, and torque value. These
can be accessed from the CD (Electronic Documentation Package) provided with your
system.
Attaching the Wires of the AC Input Housing Assembly Procedure: This procedure
may have been factory performed for you. Refer also to the procedure which follows.
The wires supplied with the AC Input Housing Assembly are attached to terminal block
TB2 and TB3 on the assembly and TB1 located within the VPS Intelligence and


remove the cover.
assembly as follows:

a) Connect the wires labeled |1| and |3| to terminal 1 of TB2. Torque to 31 in-
lbs.
b) Connect the wires labeled |2| and |4| to terminal 2 of TB2. Torque to 31 in-
lbs.
c) Connect the wires labeled |5| and |7| to terminal 1 of TB3. Torque to 31 in-
lbs.
d) Connect the wires labeled |6| and |8| to terminal 2 of TB3. Torque to 31 in-
lbs.
VPS PCU Shelf as follows. Recommended torque is 10.62 to 13.30 in-lbs.
a) Connect the wire labeled |1| to terminal 1 of TB1.
b) Connect the wire labeled |2| to terminal 2 of TB1.
c) Connect the wire labeled |3| to terminal 3 of TB1.
d) Connect the wire labeled |4| to terminal 4 of TB1.
e) Connect the wire labeled |5| to terminal 5 of TB1.
f) Connect the wire labeled |6| to terminal 6 of TB1.
g) Connect the wire labeled |7| to terminal 7 of TB1.
h) Connect the wire labeled |8| to terminal 8 of TB1.

position.
fastener.
9) Refer to the procedure which follows for AC input wiring.
Making AC Input Wiring Connections Procedure:
1) Connect AC input lugs and conductors for all PCU mounting positions to the
busbars (TB2 and TB3) located inside the AC Input Housing Assembly. Use the
supplied bolts and hardware. DO NOT use bolts longer than the supplied bolts.
Recommended torque is 50 in-lbs.

Connect Feed 1 Line 1 to the busbar designated TB2-1 and Feed 1 Line 2 to the
busbar designated TB2-2. Connect Feed 2 Line 1 to the busbar designated TB3-
1 and Feed 2 Line 2 to the busbar designated TB3-2.
Connect Feed 1 Line to the busbar designated TB2-1 and Feed 1 Neutral to the
busbar designated TB2-2. Connect Feed 2 Line to the busbar designated TB3-1
and Feed 2 Neutral to the busbar designated TB3-2.
captive fasteners. Refer to Figure 1-5C for a diagram.

AC INPUT GROUNDING CONNECTIONS

[TO VPS INTELLIGENCE AND EXPANSION SHELF(S)
SPEC. NOS. 588701300 AND 588701400]
Grounding conductors must be provided with the AC input conductors supplied to each
VPS Intelligence and Expansion Shelf.
Four 6-32 X 1/2" studs and hardware are provided in the AC Input Housing Assembly to
attach the grounding conductors to the shelf. Refer to Figure 3-1E for location. The
grounding conductors are to be terminated in a ring lug. Recommended torque is 11 in-
lbs.
Connect to earth ground, not power system neutral.
recommended wire size. These can be accessed from the CD (Electronic

FRAME GROUND CONNECTIONS

FOUR 6-32 X 1/2"
STUDS AND HARDWARE
PROVIDED ON INSIDE OF
AC INPUT HOUSING ASSEMBLY
REAR OF VPS
INTELLIGENCE SHELF
Multiple AC Input Branch Circuits

TB1B
4 3 2 1 TB1
TOP ROW
OF TB1
(top view) TB1B
TB1A
TB1A
AC INPUT FOR
BOTTOM 4 3 2 1 AC IN
PCU POSITION
ROW OF PCU 1
#1 CONNECTIONS
TB1
(top view)
AC INPUT FOR
AC IN
PCU POSITION
PCU 2
#2 CONNECTIONS
AC INPUT FOR
AC IN
PCU POSITION
PCU 3
#3 CONNECTIONS
AC INPUT FOR
AC IN
PCU POSITION
PCU 4
#4 CONNECTIONS
Figure 3-1E
Frame Ground and AC Input Connections (Spec. Nos. 588701300 and 588701400)

(INDIVIDUAL (4) AC INPUT BRANCH CIRCUITS)
[TO VPS INTELLIGENCE AND EXPANSION SHELVES
SPEC. NOS. 588701300 AND 588701400]
AC input conductors are to be provided for each individual PCU mounting position in
each VPS Intelligence and Expansion Shelf, including currently unused positions. This
wiring will ease future installation of PCUs to meet increased load requirements. These
conductors are connected to terminal block TB1, located within the VPS Intelligence and
Terminal block TB1 consists of two pieces (TB1A and TB1B) snapped into a common
housing. The TB1A and TB1B pieces are identical, and can be separated from the
common housing by gently pulling them apart.
Refer to Figure 3-1E for terminal block location and identification.
Terminal block TB1 accepts a wire size of 12 AWG maximum. Recommended torque is
6 to 8 in-lbs
system.
Procedure:
1) Pull the TB1A and TB1B pieces from the common housing (TB1). You can do
this from outside of the cabinet, or to gain more access you can remove the PCU
from mounting position #1, if installed, as detailed in a) through c) below. This is
the left most position as viewed from the front of the shelf.
a) Open the VPS Intelligence or Expansion Shelf's front door by turning and
holding the captive fastener in the counterclockwise position.
b) On the PCU to be removed, place the Standby/Operate switch to the

c) Loosen the captive fasteners secured to the front of all PCUs installed. Pivot
2) Connect AC input conductors to TB1A and TB1B as described next. TB1A and
TB1B are identical pieces. Ensure you connect all TB1A AC input conductors to
the same piece, and all TB1B conductors to the other piece.
3) Connect AC input conductors for PCU mounting position #1 to terminals TB1A-1

and TB1B-1. For 208-240 Volt AC Input Voltage Derived from a Line to Line
System: Connect Line 1 to the terminal designated TB1A-1 and Line 2 to the
terminal designated TB1B-1. For 208-240 Volt AC Input Voltage Derived from
a Line to Neutral System: Connect Line to the terminal designated TB1A-1 and
Neutral to the terminal designated TB1B-1.




7) Snap the TB1A and TB1B pieces back into the common housing (TB1). Ensure
that the AC input conductors wired to the piece designated TB1B appear on the
top row of common housing TB1, and those wired to the piece designated TB1A
appear on the bottom row of common housing TB1.

position.
d) Close the VPS Intelligence or Expansion Shelf's front door. The door can be
captive fasteners. Refer to Figure 1-5D for a diagram.

POWER INTERCONNECTIONS BETWEEN VPS INTELLIGENCE

AND EXPANSION SHELF(S), AND VPS DISTRIBUTION CABINET
ASSEMBLY [TO VPS INTELLIGENCE AND EXPANSION
SHELF(S) SPEC. NOS. 588700701, 588700801, 588703600, AND
588703700, AND VPS DISTRIBUTION CABINET ASSEMBLY]
Power interconnections between the VPS Intelligence and Expansion Shelves, and the
VPS Distribution Cabinet Assembly are made via busbars on the VPS Intelligence and
Expansion Shelves, and busbars on the VPS Distribution Cabinet Assembly. Refer to
Figures 3-1A, 3-1B, 3-1C, 3-1D, and 3-2A for locations. These connections are factory
made.
BOTTOM OF VPS
DISTRIBUTION CABINET
ASSEMBLY
FRONT VIEW
TO SYSTEM TO SYSTEM
GROUND LOAD
BUSBAR BUSBAR
VPS INTELLIGENCE/EXPANSION SHELF(S)

INTERCONNECTING BUSBARS OR CABLES 1/4-20 Studs (16)
(SUPPLIED WITH A VPS INTELLIGENCE OR
EXPANSION SHELF, AND FACTORY 0.718"
CONNECTED TO THE VPS DISTRIBUTION (4 places)
CABINET ASSEMBLY)
TO PCU SHELVES
OPTIONAL
BATTERY
CONNECTIONS
0.625"
0.625"
(3 places)
BUSBARS STUD SPACING

WHEN USED WITH
V100ICAB PCU SHELF
Figure 3-2A
DC Input Connections (VPS Distribution Cabinet Assembly)

POWER INTERCONNECTIONS BETWEEN VPS INTELLIGENCE

AND EXPANSION SHELF(S), AND VPS DISTRIBUTION CABINET
ASSEMBLY [TO VPS INTELLIGENCE AND EXPANSION
SHELF(S) SPEC. NOS. 588701300 AND 588701400, AND VPS
DISTRIBUTION CABINET ASSEMBLY]
Power interconnections between the VPS Intelligence and Expansion Shelves, and the
VPS Distribution Cabinet Assembly are made via factory provided cables on the VPS
Intelligence and Expansion Shelves, and busbars on the VPS Distribution Cabinet
Assembly. Refer to Figures 3-2A and 3-2B for locations. These connections are factory
made.
The following is provided for replacement information.
DC output conductors are connected to studs located in each VPS Intelligence and
Expansion Shelf, as described below. Recommended torque is 75 in-lbs.
Warning: The maximum torque to be applied to these studs is 80 in-lbs.
Refer to Figure 3-2B for stud location and identification. Refer also to Figure 3-2B for
stud size and dimensions.
recommended crimp lugs and wire sizes. These can be accessed from the CD
(Electronic Documentation Package) provided with your system.
Procedure:
Danger: Correct battery polarity is critical. Reversing battery leads, even for an
instant, can damage the Power Conversion Units (PCUs). Verify correct
battery polarity before installing PCUs.
2) To access the DC output studs, remove the PCUs from mounting positions #3
and #4, if installed, as detailed in a) and b) below. These are the right two
positions as viewed from the front of the shelf.

3) The studs are now visible behind PCU mounting position #4.
4) Connect the positive DC output cable (system grounded conductor) to the stud
designated with a (+) symbol in Figure 3-2B.

5) Connect the negative DC output cable to the stud designated with a (_) symbol in
Figure 3-2B.

position.
7) Close the VPS Intelligence or Expansion Shelf's front door. The door can be

FRONT OF VPS
INTELLIGENCE SHELF
DC OUTPUT CONNECTIONS
1/4-20 x 0.750" Studs (4)
POWER INTERCONNECTION TO VPS
MATING CONNECTORS AND CABLES
PROVIDED IF USED WITH A VPS
0.750" DISTRIBUTION CABINET ASSEMBLY.
(SEE DETAIL A WHEN NOT USED WITH
A VPS DISTRIBUTION CABINET
ASSEMBLY.)
0.625"
DETAIL A
DC OUTPUT STUD SIZE AND SPACING FOR
NOT USED WITH A VPS DISTRIBUTION CABINET ASSEMBLY
Figure 3-2B
DC Output Connections (Spec. Nos. 588701300 and 588701400)

EXTERNAL ALARM, REFERENCE,

AND CONTROL CONNECTIONS
[TO VPS INTELLIGENCE SHELF AND
VPS DISTRIBUTION CABINET ASSEMBLY]
recommended wire sizes and alarm relay contact ratings. These can be accessed from
the CD (Electronic Documentation Package) provided with your system.
External alarm, reference, and control conductors are connected to J8 on the VPS
Intelligence Shelf and TB1 on "Connector Assembly" circuit card 500441. Refer to
Figures 3-3 and 3-4 for connector locations and identifications, and Figures 3-5A through
3-5J for connector pinout information. (For 582120100 Lists 40 and 41, see below.)
Note: Remote Test/Equalize, Remote High Voltage Shutdown, and PCU Emergency
Shutdown and Fire Alarm Disconnect connections can be made at J8 or J9
located on the VPS Intelligence Shelf. Remote Test/Equalize and PCU
Emergency Shutdown and Fire Alarm Disconnect are internally interconnected
from J9 located on the VPS Intelligence Shelf to TB1 on "Connector Assembly"
circuit card 500441 located within the VPS Distribution Cabinet Assembly, thus
these connections can be made at J8 located on the VPS Intelligence Shelf or
TB1 located on "Connector Assembly" circuit card 500441. Connector J9 is
dedicated for VPS Distribution Cabinet Assembly interconnects, and is not
available for customer connections.
582120100 Lists 40 and 41: 582120100 Lists 40 and 41 provide an Alarm Termination
circuit card (423356900 or 423356100) inside the VPS Distribution Cabinet Assembly.
Terminal blocks J1 through J3 on the Alarm Termination circuit card are internally
interconnected to J8 on the VPS Intelligence Shelf. In this case, connectors J8 and J9 on
the VPS Intelligence Shelf are dedicated for VPS system interconnects, and are not
available for customer connections. With 582120100 Lists 40 and 41; connect external
alarm, reference, and control conductors to terminal block TB1 as described above, and
to J1 through J4 on the Alarm Termination circuit card. Refer to Figure 3-4 for connector
locations and identifications, and Figure 3-5K or 3-5L for connector pinout information.
Note: Alarm Termination circuit card 423356900 cannot be used with 588700701 and
588703600 Lists 10, 11, 12, or 16 (special application MCA).
Note: Alarm Termination circuit card 423356100 is used only with 588700701 and
588703600 List 10 (special application MCA).


TXM (Multiple Probe Concentrator Module) Connection (if required)
Procedure:
1) If furnished, connect the Battery Charge Digital Temperature Compensation

Probe or TXM (multiple probe concentrator module) to J4 located on the side of
the VPS Intelligence Shelf. Refer to Figure 3-3 for location of J4.
2) If using a TXM module, complete the remaining electrical connections to the

module per Section 5940.

Quick Connect Guide

On the following page is a Quick Connect Guide. This page may be removed and used
as an aid in making the customer external alarm, reference, and control connections to
J8 located on the VPS Intelligence Shelf.
Note that the MCA provides 9 Form-C alarm relay contacts. The configuration of these
alarm relays is determined by the MCA Configuration Number set in your system. You
can determine the MCA Configuration Number by the List Number of the VPS
Intelligence Shelf (located on the shelf's nameplate). Refer to the VPS Intelligence
Shelf's Power Data Sheet (PD) provided on the CD (Electronic Documentation Package)
furnished with your system to cross reference the Intelligence Shelf's List Number to the
MCA Configuration Number. You can also view your system's MCA Configuration
Number after power-up by following the MCA Menu Tree provided in this manual (MCA
Menu Tree Line Item "SPECNO#########" in the 'Inventory Menu'). Note that some
systems may have a Special MCA Configuration not documented in the Power Data
Sheet.

QUICK CONNECT GUIDE
EXTERNAL ALARM AND CONTROL CONNECTIONS
Page 3-32
TO J8 ON VPS INTELLIGENCE SHELF
(Standard MCA Configuration 507472)
Section 5920
* Caution: All conductors in this harness may be connected within the shelf.
Shorting or grounding of unused conductors may result in service
interruption or equipment damage. Therefore, insulate all conductor
ends not being used in your application.
Front of VPS
Intelligence Shelf
Contact State Wire Wire Contact State

During Alarm Alarm or Control Color* Color* Alarm or Control During Alarm
-- no connection Black
Red/Black AC Fail Alarm Open
-- no connection Brown 1 20 Orange/Black AC Fail Alarm Common
-- no connection Red
Yellow/Black AC Fail Alarm Close
-- System Ground (out) Orange
Green/Black Batt On Discharge Close
-- no connection Yellow
Grey/Black Batt On Discharge Common
-- no connection Green
Pink/Black Batt On Discharge Open
Chapter 3. Making Electrical Connections

-- no connection Blue
Pink/Red High Voltage Alarm 1 Close
-- Remote HVSD Purple
Pink/Blue High Voltage Alarm 1 Common
-- PCU Emergency Shutdown Grey
Pink/Green High Voltage Alarm 1 Open
-- Remote Test/Equalize White
Light Blue Major Alarm Open
Open Minor Alarm Pink
Light Blue/Black Major Alarm Common
Common Minor Alarm Light Green
Light Blue/Red Major Alarm Close
Close Minor Alarm Black/White
Light Blue/Blue MCA Audible Alarm Close
Close High Voltage Alarm 2 Brown/White
Light Blue/Green MCA Audible Alarm Common
Common High Voltage Alarm 2 Red/White
Grey/Red MCA Audible Alarm Open
Open High Voltage Alarm 2 Orange/White
Grey/Green Test/Equalize Mode Close
Close 50% Batt On Discharge Green/White 37
19 Purple/Black Test/Equalize Mode Common
Common 50% Batt On Discharge Blue/White
Blue/Black Test/Equalize Mode Open
Open 50% Batt On Discharge Purple/White J8
Spec. No. 582120100 (Model 1231V2)
QUICK CONNECT GUIDE
(Special MCA Configuration 507474)
Spec. No. 582120100 (Model 1231V2)
Front of VPS
Intelligence Shelf


Close Rectifier Major Alarm Brown/White
Common Rectifier Major Alarm Red/White
Open Rectifier Major Alarm Orange/White
37 Grey/Green Fuse / Cir. Brk. Alarm Close
Close Rectifier Minor Alarm Green/White
19 Purple/Black Fuse / Cir. Brk. Alarm Common
Common Rectifier Minor Alarm Blue/White
Blue/Black Fuse / Cir. Brk. Alarm Open
Open Rectifier Minor Alarm Purple/White J8
Page 3-33
Section 5920
QUICK CONNECT GUIDE
Page 3-34
Section 5920
Front of VPS
Intelligence Shelf

Red/Black System Current Alarm Open
-- no connection Brown 1 20 Orange/Black System Current Alarm Common
Yellow/Black System Current Alarm Close

Close High Voltage Alarm 2 Brown/White
Common High Voltage Alarm 2 Red/White
Open High Voltage Alarm 2 Orange/White
Grey/Green Fuse / Cir. Brk. Alarm Close
Close 50% Batt On Discharge Green/White 37
Common 50% Batt On Discharge Blue/White
Blue/Black Fuse / Cir. Brk. Alarm Open
Open 50% Batt On Discharge Purple/White J8
Spec. No. 582120100 (Model 1231V2)
QUICK CONNECT GUIDE
Spec. No. 582120100 (Model 1231V2)
Front of VPS
Intelligence Shelf

Red/Black AC Fail Alarm Close
Yellow/Black AC Fail Alarm Open
Green/Black Batt On Discharge Open
Pink/Black Batt On Discharge Close

Pink/Red High Voltage Alarm 1 Open
Pink/Green High Voltage Alarm 1 Close
Close Minor Alarm Pink
Open Minor Alarm Black/White
Light Blue/Blue Fuse / Cir. Brk. Alarm Close
Open MCA Fail Alarm Brown/White
Light Blue/Green Fuse / Cir. Brk. Alarm Common
Common MCA Fail Alarm Red/White
Grey/Red Fuse / Cir. Brk. Alarm Open
Close MCA Fail Alarm Orange/White
37 Grey/Green Rectifier Fail Alarm Open
Open Very Low Voltage Alarm Green/White
19 Purple/Black Rectifier Fail Alarm Common
Common Very Low Voltage Alarm Blue/White
Blue/Black Rectifier Fail Alarm Close
Close Very Low Voltage Alarm Purple/White J8
Page 3-35
Section 5920
QUICK CONNECT GUIDE
Page 3-36
Section 5920
Front of VPS
Intelligence Shelf


Pink/Red Test/Equalize 2 Close
Pink/Blue Test/Equalize 2 Common
Pink/Green Test/Equalize 2 Open
Light Blue/Blue LVD Alarm Close
Close Fuse / Cir. Brk. Alarm Brown/White
Light Blue/Green LVD Alarm Common
Common Fuse / Cir. Brk. Alarm Red/White
Grey/Red LVD Alarm Open
Open Fuse / Cir. Brk. Alarm Orange/White
Grey/Green Test/Equalize Mode Close
Close AC Fail Major Alarm Green/White 37
Common AC Fail Major Alarm Blue/White
Blue/Black Test/Equalize Mode Open
Open AC Fail Major Alarm Purple/White J8
Spec. No. 582120100 (Model 1231V2)
QUICK CONNECT GUIDE
Spec. No. 582120100 (Model 1231V2)
Front of VPS
Intelligence Shelf


Light Blue/Blue MCA Fail Alarm Close
Open PCU Fail Major Alarm Brown/White
Light Blue/Green MCA Fail Alarm Common
Common PCU Fail Major Alarm Red/White
Grey/Red MCA Fail Alarm Open
Close PCU Fail Major Alarm Orange/White
37 Grey/Green Test/Equalize Mode Open
Open PCU Fail Minor Alarm Green/White
Common PCU Fail Minor Alarm Blue/White
Blue/Black Test/Equalize Mode Close
Close PCU Fail Minor Alarm Purple/White J8
Page 3-37
Section 5920
QUICK CONNECT GUIDE
Page 3-38
Section 5920
Front of VPS
Intelligence Shelf

Red/Black High Voltage Alarm Close
-- no connection Brown 1 20 Orange/Black High Voltage Alarm Common
Yellow/Black High Voltage Alarm Open
Green/Black Low Float Open
Grey/Black Low Float Common
Pink/Black Low Float Close

Pink/Red High Float Open
Pink/Blue High Float Common
Pink/Green High Float Close
Light Blue/Blue Low Voltage Alarm Close
Open Multiple Rectifier Fail Alarm Brown/White
Light Blue/Green Low Voltage Alarm Common
Common Multiple Rectifier Fail Alarm Red/White
Grey/Red Low Voltage Alarm Open
Close Multiple Rectifier Fail Alarm Orange/White
37 Grey/Green Fuse Alarm Open
Open 1 Rectifier Fail Alarm Green/White
19 Purple/Black Fuse Alarm Common
Common 1 Rectifier Fail Alarm Blue/White
Blue/Black Fuse Alarm Close
Close 1 Rectifier Fail Alarm Purple/White J8
Spec. No. 582120100 (Model 1231V2)
QUICK CONNECT GUIDE
Spec. No. 582120100 (Model 1231V2)
Front of VPS
Intelligence Shelf


Light Blue PCU Fail Major Alarm Open
Close PCU Fail Minor Alarm Pink
Light Blue/Black PCU Fail Major Alarm Common
Common PCU Fail Minor Alarm Light Green
Light Blue/Red PCU Fail Major Alarm Close
Open PCU Fail Minor Alarm Black/White
Light Blue/Blue MCA Fail Alarm Close
Open High Voltage Alarm 2 Brown/White
Light Blue/Green MCA Fail Alarm Common
Common Hign Voltage Alarm 2 Red/White
Grey/Red MCA Fail Alarm Open
Close High Voltage Alarm 2 Orange/White
37 Grey/Green Fuse / Cir. Brk. Alarm Open
Open Very Low Voltage Alarm Green/White
Common Very Low Voltage Alarm Blue/White
Blue/Black Fuse / Cir. Brk. Alarm Close
Close Very Low Voltage Alarm Purple/White J8
Page 3-39
Section 5920

PCU INTELLIGENCE AND EXPANSION

SHELVES INTERCONNECT CONNECTORS
J11 J12
1 11 1 11
5 15 5 15

J4
1 3
2 4
DIGITAL PROBE / TXM
CONNECTOR
(Except V100ICAB)
FRONT OF VPS
INTELLIGENCE SHELF
(VPS EXPANSION SHELF
SIMILAR EXCEPT ONLY 1 20
CONNECTORS J11 AND J12)
MCA INTERFACE OPTION 1 14

EITHER ...
MODEM RS-232
Port
(FOR REMOTE ACCESS
VIA VORTEX WINLINK)
19 37
(PHONE LINE CONNECTOR) Modem
RS-232 Port 13 25
(FOR LOCAL/REMOTE ACCESS J8
RS-232/Modem
VIA VORTEX WINLINK) Option J9 EXTERNAL ALARM,
(RJ-45 CONNECTOR) REFERENCE, AND
VORTEX DISTRIBUTION
RS-485 CONTROL CONNECTOR
ALARM, REFERENCE,
(FOR INTERFACE TO SMART
AND CONTROL
MONITORING SYSTEM SUCH AS
INTERCONNECT
VORTEX SMART OR SMART DGU) CONNECTOR
(RJ-45 CONNECTOR)
RS-232/MODEM
(FOR LOCAL/REMOTE ACCESS
VIA VORTEX WINLINK)
(9-PIN FEMALE D-TYPE CONNECTOR
AND PHONE LINE CONNECTOR)
ETHERNET
VIA VORTEX WINLINK)
(RJ-45 CONNECTOR,
LOCATED ON SIDE OF OPTION)
Figure 3-3
VPS Intelligence Shelf and Expansion Shelf Connector Locations and Identification

Page 3-42
Section 5920
TERMINAL BLOCK TB1
EXTERNAL ALARM, REFERENCE, AND

CONTROL CONNECTIONS (MAIN BAY ONLY)
CONNECTOR
ASSEMBLY
A5 CIRCUIT CARD
TB1 (500441)
LOAD D BUS
A6 INTERNAL VPS
A1 DISTRIBUTION
LOAD C BUS CABINET ASSEMBLY
J8 J9 J10 J3 CONNECTIONS
A7 NOTE: IF THIS CABINET SEE DETAIL A

A2 CONTAINS NO
LOAD B BUS LOW VOLTAGE
DISCONNECT, A
FACTORY CONNECTION
A8 IS PROVIDED TO
LOAD A BUS JUMPER J3-1 TO J3-6.
A3
J1 J2
A9
A4
A10 ALARM, REFERENCE, AND CONTROL

INTERCONNECTIONS TO MCA OR
TO/FROM OTHER VPS DISTRIBUTION
CABINET ASSEMBLIES.


ALARM TERMINATION CIRCUIT CARD
(423356900 or 423356100)
(laying flat in cabinet)

SEE
(582120100 Lists 40 and 41 only) DETAIL B
(423356900)
J8 - ALARM
(423356900 shown, 423356100 alarm or
INTERCONNECTIONS
relay contacts vary from those shown) DETAIL C
TO MCA
(423356100)
VPS Distribution Cabinet Assembly Connector Locations and Identifications

TERMINAL BLOCKS J1 THROUGH J4
EXTERNAL ALARM CONNECTIONS
Spec. No. 582120100 (Model 1231V2)
EXTERNAL INTERNALLY EMERGENCY

SYSTEM FUSED SHUTDOWN
VOLTAGE EXTERNAL AND FIRE ALARM
VOLTAGE
METER READING VOLTAGE DISCONNECT
SOURCE
SENSING SYSTEM
FUSE
REMOTE SYSTEM SYSTEM SYSTEM SYSTEM ALARM
TEST/EQ V OUT RETURN +SNS -SNS RETURN V OUT INPUT
TB1
1 2 3 4 5 6 7 8 9 10 11 12
TO EXTERNAL CIRCUITS
VPS INTELLIGENCE
AND EXPANSION SHELVES
INTERCONNECTIONS
To VPS Intelligence Shelf
J11 OR J12 OF VPS
INTELLIGENCE SHELF TO CIRCUIT CARD (500441)
J8, J9, OR J10 ON "CONNECTOR
ASSEMBLY" CIRCUIT CARD 500441
(IN MAIN BAY ONLY)
Between Bays
J11 OR J12 OF TOP MOST VPS PCU J8 J9 J10 J3
SHELF IN RACK TO J8, J9, OR J10 ON INTERNAL VPS
"CONNECTOR ASSEMBLY" CIRCUIT DISTRIBUTION
CARD 500441 (IN MAIN BAY ONLY) CABINET ASSEMBLY
CONNECTIONS
J1 J2
TO J2 ON ADDITIONAL TO J9 ON VPS INTELLIGENCE SHELF IF

VPS DISTRIBUTION CABINET FIRST VPS DISTRIBUTION CABINET
ASSEMBLY, IF REQUIRED, ASSEMBLY. IF THIS IS A SUBSEQUENT
VPS DISTRIBUTION CABINET ASSEMBLY,
FROM J1 ON THE PREVIOUS VPS
ALARM, REFERENCE, AND CONTROL

INTERCONNECTIONS TO ANOTHER VPS
DETAIL A DISTRIBUTION CABINET ASSEMBLY AND/OR TO
VPS INTELLIGENCE SHELF. MATING CONNECTOR
AND WIRE HARNESS PROVIDED WITH THE VPS.
Figure 3-4 (cont'd from previous page, cont'd on next page)


582120100 Lists 40 and 41 Only

ALARM TERMINATION CIRCUIT CARD 423356900
(CANNOT BE USED WITH SPECIAL APPLICATION MCA)
J1 through J4
TO J8 ON VPS
INTELLIGENCE SHELF
CONV MJ-NO TEST/EQ-NC

Converter
Test/
Major CONV MJ-COM TEST/EQ-COM
Eq*
Alarm*
CONV MJ-NC TEST/EQ-NO
CONV MN-NO AUD-NO

Converter
Audible
Minor CONV MN-COM AUD-COM
Alarm**
Alarm*
CONV MN-NC AUD-NC
MN-NO MJ-NO
Minor Major
MN-COM MJ-COM
Alarm* Alarm**
MN-NC MJ-NC
HVA2-NO HV-NC
High High
Voltage HVA2-COM HV-COM Voltage
Alarm 2* Alarm 1*
HVA2-NC HV-NO
50% DISCHARGE-NO LV-NC

50% Battery Battery On
On Discharge 50% DISCHARGE-COM LV-COM Discharge
Alarm* Alarm*
50% DISCHARGE-NC LV-NO
A/C FAIL-NC
AC
A/C FAIL-COM Fail
Notes
Alarm*
A/C FAIL-NO
* These relay contacts are deenergized during normal operation,
and energized during an alarm condition.
** These relay contacts are energized during normal operation,

and deenergized during an alarm condition.
All relay contacts are shown with the relays deenergized. See text DETAIL B
for operating status before making connections.
Figure 3-4 (cont'd from previous page, cont'd on next page)


582120100 Lists 40 and 41 Only

ALARM TERMINATION CIRCUIT CARD 423356100
(USED WITH SPECIAL APPLICATION MCA)
J1 through J4
TO J8 ON VPS
INTELLIGENCE SHELF
CONV MJ-NO FUSE-NC

Converter
Fuse
Major CONV MJ-COM FUSE-COM
Alarm*
Alarm*
CONV MJ-NC FUSE-NO
CONV MN-NO AUD-NO

Converter
Audible
Minor CONV MN-COM AUD-COM
Alarm**
Alarm*
CONV MN-NC AUD-NC
MN-NO MJ-NO
Minor Major
MN-COM MJ-COM
Alarm* Alarm**
MN-NC MJ-NC
RECT MJ-NO HV-NC

Rectifier High
Major RECT MJ-COM HV-COM Voltage
Alarm* Alarm*
RECT MJ-NC HV-NO
RECT MN-NO LV-NC

Rectifier Low
Minor RECT MN-COM LV-COM Voltage
Alarm* Alarm*
RECT MN-NC LV-NO
A/C FAIL-NC
AC
A/C FAIL-COM Fail
Notes Alarm*
A/C FAIL-NO
* These relay contacts are deenergized during normal operation,
and energized during an alarm condition.
** These relay contacts are energized during normal operation,

and deenergized during an alarm condition.
All relay contacts are shown with the relays deenergized. See text DETAIL C
for operating status before making connections.



500441 (located inside the main VPS Distribution Cabinet Assembly)
(all Lists)
Terminal block TB1 is a screw-clamp type connector and is located inside the main VPS
Distribution Cabinet Assembly on "Connector Assembly" circuit card 500441. Refer to
Figure 3-4 for connector location, and Figure 3-5A for connector pinouts.
Terminal block TB1 accepts a wire size in the range of 22-16 gauge, and recommended
torque is 2.0-2.2 in-lbs.
Note: A circuit card 500441 is located in each VPS Distribution Cabinet Assembly. Only
make connections to TB1 on circuit card 500441 located in the main VPS
Distribution Cabinet Assembly (the one connected to the MCA).
Procedure:
1) Remote Test/Equalize: Customer furnished system ground applied to terminal

1 of TB1 on "Connector Assembly" circuit card 500441 located within the VPS
Distribution Cabinet Assembly (or terminal 10 of J8 located on the VPS
Intelligence Shelf) places all PCUs into the test/equalize mode of operation.
Removal of the signal places all PCUs into the float mode of operation.
Note: This connection can also be made to same terminal on any other
"Connector Assembly" circuit card which may be connected to this circuit
card.
2) External System Voltage Meter Reading: If desired, extend external system

voltage meter reading leads from the voltage source to be read to terminals 2
(battery) and 3 (return) of TB1 on "Connector Assembly" circuit card 500441
located within the Main VPS Distribution Cabinet Assembly. This is the voltage
source the MCA monitors for system alarms and displays as "System Output
Voltage".
Warning: Equipment damage may result if leads are connected to the

wrong terminals of TB1.
Note: Ensure the Internal/External System Voltage Meter Reading circuit card
on "Connector Assembly" circuit card 500441 is in the EXT position, as
previously described in "Chapter 2. Setting System Wiring Options".
Note: System Voltage Meter Reading leads are factory connected to the cabinet
assembly's output busbars when Internal/External Voltage System
Voltage Meter Reading circuit card located on "Connector Assembly"
circuit card 500441 is in the INT position, as previously described in
"Chapter 2. Setting System Wiring Options".
Note: This connection cannot be made to same terminals on any other

card.

3) External Voltage Sensing: If a battery charge temperature compensation

module is used with this system, skip this procedure and refer to the next
procedure detailed in "LORAIN® Battery Charge Temperature Compensation
Module".

Note: Ensure the Internal/External Voltage Sensing circuit card located on

"Connector Assembly" circuit card 500441 is in the EXT position, as
Note: External voltage sensing lead connections must be made to the SYSTEM
side of any battery protective or disconnect devices present.
Note: Sense leads are factory connected to the cabinet assembly's output
busbars when Internal/External Voltage Sensing circuit card located on
"Connector Assembly" circuit card 500441 is in the INT position, as
If desired, extend external voltage sensing leads from the battery or other voltage
sense location to terminals 4 (positive) and 5 (negative) of TB1 on "Connector
Assembly" circuit card 500441 located within the Main VPS Distribution Cabinet
Assembly. If the external voltage sensing leads originate from a location other
than a battery charge temperature compensation module, they should be fused
at 1-1/3 amperes. If the external voltage sensing leads originate from a battery
charge temperature compensation module, a fuse is already provided on the
module.
Note: This connection cannot be made to same terminals on any other

card.

4) LORAIN® Battery Charge Temperature Compensation Module (if

furnished): If a battery charge temperature compensation module is not used
with this system, skip this procedure.
Caution: Turn off all PCUs before removing any leads from a previously
installed battery charge temperature compensation module.

Note: Battery Charge Temperature Compensation Module Part No. 433867000

cannot be used in systems with more than 20 PCUs.
Note: When adding a Battery Charge Temperature Compensation Module to a

system that has been previously operated, follow the procedures outlined
in the "Operating Procedures" chapter of the separate User Manual. If
these steps are not followed, the system will go into high voltage
shutdown when the system is restarted.
If desired, connect leads between the battery charge temperature compensation

module and the system’s external voltage sensing terminals, and leads from the
battery charge temperature compensation module to the battery, as described in
the following procedure.
Electrical connections to the battery charge temperature compensation module

are made via a terminal assembly that is factory connected to the module. This
terminal assembly should not be removed from the module. Wires are
connected to terminals on this assembly using customer-furnished insulated 1/4”
right-angle push-on connectors (Part No. 245366900 or equivalent). These
connectors accept a wire size in the range of 22-18 AWG. Recommended wire
size is 22 AWG. Use a hand crimping tool (AMP Part. No. 58078-3 with Die No.
90390-3, or equivalent) to install a connector onto a wire. Following the
instructions provided with the crimp tool or connectors.
Note: Ensure the Internal/External Voltage Sensing circuit card located on

"Connector Assembly" circuit card 500441 is in the EXT position, as
Note: Use the specified insulated right-angle (flag-type) connectors to allow

clearance between the wiring and the plastic terminal shield.
Note: Battery charge temperature compensation module battery connections

must be made to the SYSTEM side of any battery protective or
disconnect devices present.
a) Remove the terminal shield from the terminal assembly of the battery charge
temperature compensation module by removing the two screws securing it.
b) Extend a lead from terminal 4 of TB1 on "Connector Assembly" circuit card

500441 located within the Main VPS Distribution Cabinet Assembly to
terminal TB6 (+SNS) located on the battery charge temperature
compensation module’s terminal assembly.

Note: This connection cannot be made to same terminal on any other

"Connector Assembly" circuit card which may be connected to this
circuit card.
c) Extend a lead from terminal 5 of TB1 on "Connector Assembly" circuit card

500441 located within the Main VPS Distribution Cabinet Assembly to
terminal TB8 (-SNS) located on the battery charge temperature compensation
module’s terminal assembly.
Note: This connection cannot be made to same terminal on any other

"Connector Assembly" circuit card which may be connected to this
circuit card.
d) Extend a lead from terminal TB7 (-BAT) located on the battery charge
temperature compensation module’s terminal assembly to the negative
terminal of the battery.
e) Extend a lead from terminal TB5 (+BAT) located on the battery charge
temperature compensation module’s terminal assembly to the positive
terminal of the battery.
f) Secure the terminal shield to the terminal assembly of the battery charge
temperature compensation module, using the screws removed in step b).
Refer to Figure 2-7 for installation details.
5) Internally Fused Voltage Source for Connection to SMART Equipment

and/or Battery Thermal Runaway Management System: Terminal 7 of TB1
on "Connector Assembly" circuit card 500441 located within the Main VPS
Distribution Cabinet Assembly is internally connected to 5 ampere fuse A (F1)
located on the inside left side panel of the Main VPS Distribution Cabinet
Assembly. This fuse is connected to system output. If desired, connect the input
of a SMART System and/or Battery Thermal Runaway Management System to
this terminal. Terminal 6 of TB1 on "Connector Assembly" circuit card 500441
located within the Main VPS Distribution Cabinet Assembly is provided for the
return connection. Leads may be factory connected to these terminals.

6) Emergency Shutdown and Fire Alarm Disconnect: Customer furnished

system ground applied to terminal 10 of TB1 on "Connector Assembly" circuit
card 500441 located within the VPS Distribution Cabinet Assembly (or terminal 9
of J8 on the VPS Intelligence Shelf) inhibits all PCUs.
If low voltage disconnect is furnished and is also to be controlled by the

emergency shutdown and fire alarm disconnect switch, connect an external
Form-C Emergency Stop switch to TB1 on "Connector Assembly" circuit card
500441 located within the VPS Distribution Cabinet Assembly. Connect an
external Form-C Emergency Stop switch to TB1. Connect the normally close
contacts between TB1-8 and TB1-9. Connect the normally open contacts
between TB1-9 and TB1-10. Activating the switch inhibits all PCUs, and
disconnects the battery and system output from the controlled load(s).
Note: If low voltage disconnect is furnished and an emergency stop switch is not
required, for proper low voltage disconnect operation, jumper TB1-8 to
TB1-9.
Note: Remove any jumpers from TB1-8, 9, and 10 on all other "Connector
Assembly" circuit cards which may be connected to this circuit card.
Note: This connection can also be made to same terminals on any other
card.
7) System Fuse Alarm Input: The system fuse alarm circuit activates when a ±18
to 60 volts DC signal is applied to terminal 11 of TB1 on "Connector Assembly"
circuit card 500441 located within the VPS Distribution Cabinet Assembly.
card.

Power System Circuits TB1
Remote Test/Equalize* 1
BATTERY 2
External System Voltage Meter Reading
RETURN 3
+SNS 4
External Voltage Sensing
-SNS 5
Fuse A (F1) Return 6
Internally Fused Voltage Source
Fuse A (F1) 7
8
Emergency Shutdown and
9
Fire Alarm Disconnect*
10
System Fuse Alarm Input 11
12
TERMINAL BLOCK TB1 ON "CONNECTOR ASSEMBLY" CIRCUIT CARD

500441 LOCATED WITHIN THE MAIN VPS DISTRIBUTION CABINET
ASSEMBLY (ALL LISTS)
* These connections can be made at J8 located on the VPS

Intelligence Shelf or TB1 on Connector Assembly circuit card
500441 located within the main VPS Distribution Cabinet
Assembly.
Note: Battery Charge Temperature

Compensation Module Part No.
433867000 cannot be used in
systems with more than 20 PCU's.
TB6 (+SNS) (+BAT) TB5
Optional Lorain Battery Charge +

Temperature Compensation Module** Battery
-
TB8 (-SNS) (-BAT) TB7
** See Note in Battery Charge

Temperature Compensation Module
Wiring Procedure, when being Installed
in a Previously Operated System.
Figure 3-5A
External Alarm, Reference, and Control Connections (TB1 on Connector Assembly
Circuit Card 500441 Located in Main VPS Distribution Cabinet Assembly) (All Lists)

Connections to J8 on VPS Intelligence Shelf

Note that the MCA provides 9 Form-C alarm relay contacts. The configuration of these
alarm relays is determined by the MCA Configuration Number set in your system. You
can determine the MCA Configuration Number by the List Number of the VPS
Intelligence Shelf (located on the shelf's nameplate). Refer to the VPS Intelligence
Shelf's Power Data Sheet (PD) provided on the CD (Electronic Documentation Package)
furnished with your system to cross reference the Intelligence Shelf's List Number to the
MCA Configuration Number. You can also view your system's MCA Configuration
Number after power-up by following the MCA Menu Tree provided in this manual (MCA
Menu Tree Line Item "SPECNO#########" in the 'Inventory Menu'). Note that some
systems may have a Special MCA Configuration not documented in the Power Data
Sheet.
Connector J8 is a subminiature D-type connector and is located on the right side panel of
the VPS Intelligence Shelf. Refer to Figure 3-3 for connector location, and Figure 3-5 for
connector pinouts. A “Quick Connect Guide” is also provided at the beginning of this
section.
A mating connector and wire harness (fifteen feet in length) is furnished which connects
to J8 on the VPS Intelligence Shelf, and provides leads which can be spliced to customer
leads. Splice these leads as described below. The color scheme for this wire harness is
shown in Figure 3-5. This wire harness cannot be used with 582120100 Lists 40 and 41.
Caution: All conductors in this harness may be connected within the shelf.
(MCA Configuration 507472)
1) Remote High Voltage Shutdown: Customer furnished system ground applied

to terminal 8 of J8 located on the VPS Intelligence Shelf (or terminal 25 of J9)
activates the internal high voltage shutdown circuit on all PCUs.

system ground applied to terminal 9 of J8 located on the VPS Intelligence Shelf
(or terminal 10 of TB1 on "Connector Assembly" circuit card 500441 located
within the VPS Distribution Cabinet Assembly) inhibits all PCUs.

emergency shutdown and fire alarm disconnect switch, use the terminals of TB1
on "Connector Assembly" circuit card 500441 located within the VPS Distribution
Cabinet Assembly. Connect an external Form-C Emergency Stop switch to TB1.
Connect the normally close contacts between TB1-8 and TB1-9. Connect the
normally open contacts between TB1-9 and TB1-10. Activating the switch
inhibits all PCUs, and disconnects the battery and system output from the
controlled load(s).
TB1-9.

card.

10 of J8 located on the VPS Intelligence Shelf (or terminal 1 of TB1 on
"Connector Assembly" circuit card 500441 located within the VPS Distribution
Cabinet Assembly) places all PCUs into the test/equalize mode of operation.
card.
4) Minor Alarm: A close loop circuit is provided between terminals 12 and 13 of J8

located on the VPS Intelligence Shelf, and an open loop circuit is provided
between terminals 11 and 12 of J8 located on the VPS Intelligence Shelf during
an alarm condition.
5) High Voltage Alarm 2: A close loop circuit is provided between terminals 14

and 15 of J8 located on the VPS Intelligence Shelf, and an open loop circuit is
provided between terminals 15 and 16 of J8 located on the VPS Intelligence
Shelf during an alarm condition.
6) 50% Battery On Discharge Alarm: A close loop circuit is provided between

terminals 17 and 18 of J8 located on the VPS Intelligence Shelf, and an open
loop circuit is provided between terminals 18 and 19 of J8 located on the VPS
Intelligence Shelf during an alarm condition.
7) AC Fail Alarm: A close loop circuit is provided between terminals 21 and 22 of

J8 located on the VPS Intelligence Shelf, and an open loop circuit is provided
an alarm condition.
8) Battery On Discharge Alarm: A close loop circuit is provided between


10) Major Alarm: A close loop circuit is provided between terminals 30 and 31 of J8
an alarm condition.
11) MCA Audible Alarm: A close loop circuit is provided between terminals 32 and
33 of J8 located on the VPS Intelligence Shelf, and an open loop circuit is

Shelf during any alarm condition. These terminals may be factory connected to
an audible alarm circuit.
12) Test/Equalize: A close loop circuit is provided between terminals 35 and 36 of

between terminals 36 and 37 of J8 located on the VPS Intelligence Shelf when
the system is placed in the test/equalize mode (locally or remotely).
13) System Ground: System ground is supplied at terminal 4 of J8 located on the

VPS Intelligence Shelf for connection into customer's alarm circuits, if required.


MCA CONFIGURATION 507472
Alarm J8 Accessory Accessory J8 Alarm
or Pin Harness 1 20 Harness Pin or
Control Wire Colors 4 Wire Colors 4 Control
(No Connection) 1 Black Red/Black 20
(No Connection) 2 Brown Orange/Black 21 AC Fail
Alarm 1
(No Connection) 3 Red Yellow/Black 22
System Ground 4 Orange Green/Black 23
Battery On
(No Connection) 5 Yellow Slate/Black 24 Discharge
(No Connection) 6 Green Pink/Black 25 Alarm 1
(No Connection) 7 Blue Pink/Red 26

Remote HVSD 8 Violet Pink/Blue 27 High Voltage
Alarm 1 1
PCU Emergency Shutdown 3 9 Slate Pink/Green 28
3
Remote Test/Equalize 10 White Lt. Blue 29
11 Pink Lt. Blue/Black 30 Major Alarm 2
Minor Alarm 1 12 Lt. Green Lt. Blue/Red 31
13 Black/White Lt. Blue/Blue 32
14 Brown/White Lt. Blue/Green 33 MCA Audible
High Voltage Alarm 2
15 Red/White Slate/Red 34
Alarm 2 1
16 Orange/White Slate/Green 35
17 Green/White Violet/Black 36 Test/
50% Battery 19 37 Equalize 1
On Discharge 18 Blue/White J8 Blue/Black 37
Alarm 1
19 Violet/White
J8 LOCATED ON SIDE OF VPS INTELLIGENCE SHELF
Notes:
1
These relays are de-energized during normal operation, and energized during an alarm condition.
2
These relays are energized during normal operation, and de-energized during an alarm condition.
3
These connections can be made at J8 located on the VPS Intelligence Shelf, or TB1 on Connector
Assembly circuit card 500441 located within the main VPS Distribution Cabinet Assembly.
4
Wire Lead Colors if using Accessory J8 Wire Harness.
Caution: All conductors in the Accessory Wire Harness may be connected within the shelf. Shorting
or grounding of unused conductors may result in service interruption or equipment damage.
Therefore, insulate all conductor ends not being used in your application.
All relay contacts are shown with the relays de-energized. Normally Open Contact
See text for operating status before making connections. Common
Normally Closed Contact
Figure 3-5B
External Alarm and Control Connections (J8 on VPS Intelligence Shelf)
(MCA CONFIGURATION 507472)




controlled load(s).
TB1-9.
card.

card.

an alarm condition.
5) Rectifier Major Alarm: A close loop circuit is provided between terminals 14

6) Rectifier Minor Alarm: A close loop circuit is provided between terminals 17



an alarm condition.


an alarm condition.
12) Fuse Alarm/Circuit Breaker Alarm: A close loop circuit is provided between



Alarm 1
Battery On

Alarm 1 1
3
Rectifier Major Alarm 2
Alarm 1
Fuse Alarm/
17 Green/White 19 37 Violet/Black 36 Circuit Breaker
Rectifier Minor
18 Blue/White J8 Blue/Black 37 Alarm 1
Alarm 1
19 Violet/White
Notes:
1
2
3
4
Figure 3-5C




controlled load(s).
TB1-9.
card.

card.

an alarm condition.



7) System Current Alarm: A close loop circuit is provided between terminals 21



an alarm condition.



(No Connection) 1 Black Red/Black 20 System
(No Connection) 2 Brown Orange/Black 21 Current
(No Connection) 3 Red Yellow/Black 22 Alarm 1
Battery On

Alarm 1 1
3
Alarm 2 1
Fuse Alarm/
50% Battery
On Discharge 18 Blue/White J8 Blue/Black 37 Alarm 1
Alarm 1
19 Violet/White
Notes:
1
2
3
4
Figure 3-5D




controlled load(s).
TB1-9.
card.

card.

an alarm condition.
5) MCA Fail Alarm: A close loop circuit is provided between terminals 15 and 16 of
an alarm condition.
6) Very Low Voltage Alarm: A close loop circuit is provided between terminals 18


an alarm condition.


an alarm condition.
12) Rectifier Fail Alarm: A close loop circuit is provided between terminals 36 and



Alarm 2
Battery On

Alarm 1 2
3
13 Black/White Lt. Blue/Blue 32 Fuse Alarm/
14 Brown/White Lt. Blue/Green 33 Circuit Breaker
MCA Fail
15 Red/White Slate/Red 34 Alarm 2
Alarm 2
17 Green/White Violet/Black 36 Rectifier Fail
Very Low 19 37 Alarm 2
Voltage 18 Blue/White J8 Blue/Black 37
Alarm 2
19 Violet/White
Notes:
1
2
3
4
Figure 3-5E




controlled load(s).
TB1-9.
card.

card.

an alarm condition.
5) Fuse Alarm / Circuit Breaker Alarm: A close loop circuit is provided between
6) AC Fail Major Alarm: A close loop circuit is provided between terminals 17 and


an alarm condition.

9) Test/Equalize 2: A close loop circuit is provided between terminals 26 and 27 of

an alarm condition.
11) LVD Alarm: A close loop circuit is provided between terminals 32 and 33 of J8
any alarm condition.




Alarm 1
Battery On

Remote HVSD 8 Violet Pink/Blue 27 Test/
Equalize 2 1
3
14 Brown/White Lt. Blue/Green 33 LVD
Fuse Alarm/ Alarm 2
Circuit Breaker 15 Red/White Slate/Red 34
Alarm 1
17 Green/White 19 37 Violet/Black 36 Test/Equalize 1
AC Fail
Major Alarm 1
18 Blue/White J8 Blue/Black 37
19 Violet/White
Notes:
1
2
3
4
Figure 3-5F




controlled load(s).
TB1-9.
card.

card.

an alarm condition.
5) PCU Fail Major Alarm: A close loop circuit is provided between terminals 15
6) PCU Fail Minor Alarm: A close loop circuit is provided between terminals 18


an alarm condition.


an alarm condition.
an alarm condition.




Alarm 2
Battery On

Alarm 1 2
3
14 Brown/White Lt. Blue/Green 33 MCA Fail
PCU Fail Alarm 2
Major Alarm 2
17 Green/White 19 37 Violet/Black 36 Test/Equalize 2
PCU Fail
Minor Alarm 2
19 Violet/White
Notes:
1
2
3
4
Figure 3-5G




controlled load(s).
TB1-9.
card.

card.

an alarm condition.
5) Multiple Rectifier Fail Alarm: A close loop circuit is provided between terminals
15 and 16 of J8 located on the VPS Intelligence Shelf, and an open loop circuit is
6) 1 Rectifier Fail Alarm: A close loop circuit is provided between terminals 18


7) High Voltage Alarm: A close loop circuit is provided between terminals 20 and
8) Low Float Alarm: A close loop circuit is provided between terminals 24 and 25
of J8 located on the VPS Intelligence Shelf, and an open loop circuit is provided
an alarm condition.
9) High Float Alarm: A close loop circuit is provided between terminals 27 and 28
of J8 located on the VPS Intelligence Shelf, and an open loop circuit is provided
an alarm condition.
an alarm condition.
11) Low Voltage Alarm: A close loop circuit is provided between terminals 32 and
12) Fuse Alarm: A close loop circuit is provided between terminals 36 and 37 of J8
an alarm condition.



(No Connection) 2 Brown Orange/Black 21 High Voltage
Alarm 2
(No Connection) 5 Yellow Slate/Black 24 Low Float
Alarm 2
(No Connection) 6 Green Pink/Black 25
Remote HVSD 8 Violet Pink/Blue 27 High Float
Alarm 2
3
14 Brown/White Lt. Blue/Green 33 Low Voltage
Multiple Rectifier Alarm 2
Fail Alarm 2
17 Green/White 19 37 Violet/Black 36 Fuse Alarm 2
1 Rectifier
Fail Alarm 2
19 Violet/White
Notes:
1
2
3
4
Figure 3-5H




controlled load(s).
TB1-9.
Assembly" circuit cards that may be connected to this circuit card.
"Connector Assembly" circuit card that may be connected to this circuit
card.

"Connector Assembly" circuit card that may be connected to this circuit
card.
4) PCU Fail Minor Alarm: A close loop circuit is provided between terminals 11

6) Very Low Voltage Alarm: A close loop circuit is provided between terminals 18


an alarm condition.


10) PCU Fail Major Alarm: A close loop circuit is provided between terminals 30
an alarm condition.


EXTERNAL ALARM, REFERENCE, AND CONTROL CONNECTIONS

Alarm 2
Battery On

Alarm 1 2
3
11 Pink Lt. Blue/Black 30 PCU Fail
PCU Fail Major Alarm 2
12 Lt. Green Lt. Blue/Red 31
Minor Alarm 2
14 Brown/White Lt. Blue/Green 33 MCA Fail
Alarm 2 2
Fuse Alarm/
Very Low
Voltage 18 Blue/White J8 Blue/Black 37 Alarm 2
Alarm 2
19 Violet/White
Notes:
1
2
3
4
Normally Close Contact
Figure 3-5J
External Alarm, Reference, and Control Connections (J8 on VPS Intelligence Shelf)

Connections to Terminal Blocks J1-J4 on Alarm

Termination Circuit Card 423356900 Procedure
(582120100 Lists 40 and 41 only):
Refer to Figure 3-4 for connector location, and Figure 3-5K for connector pinouts.
Terminal blocks J1-J4 accept a maximum wire size of 14 gauge, and recommended
torque is 9 in-lbs. Recommended wire size is 22 AWG for loop lengths up to 200' and
18-20 AWG for loop lengths over 200'.
1) Test/Equalize: A close loop circuit is provided between terminals

TEST/EQ-COM and TEST/EQ-NO of J1 on Alarm Termination circuit card
423356900 located within the VPS Distribution Cabinet Assembly, and an open
loop circuit is provided between terminals TEST/EQ-NC and TEST/EQ-COM of
J1 on Alarm Termination circuit card 423356900 located within the VPS
Distribution Cabinet Assembly when the system is placed in the test/equalize
mode (locally or remotely).
2) Audible Alarm: A close loop circuit is provided between terminals AUD-NC and
AUD-COM of J1 on Alarm Termination circuit card 423356900 located within the
VPS Distribution Cabinet Assembly, and an open loop circuit is provided between
terminals AUD-COM and AUD-NO of J1 on Alarm Termination circuit card
423356900 located within the VPS Distribution Cabinet Assembly during any
alarm condition. These terminals may be factory connected to an audible alarm
circuit.
3) Major Alarm: A close loop circuit is provided between terminals MJ-NC and
MJ-COM of J1/J2 on Alarm Termination circuit card 423356900 located within
the VPS Distribution Cabinet Assembly, and an open loop circuit is provided
between terminals MJ-COM and MJ-NO of J2 on Alarm Termination circuit card
423356900 located within the VPS Distribution Cabinet Assembly during an
alarm condition.
4) High Voltage Alarm 1: A close loop circuit is provided between terminals

HV-COM and HV-NO of J2 on Alarm Termination circuit card 423356900 located
within the VPS Distribution Cabinet Assembly, and an open loop circuit is
provided between terminals HV-NC and HV-COM of J2 on Alarm Termination
circuit card 423356900 located within the VPS Distribution Cabinet Assembly
during an alarm condition.

terminals LV-COM and LV-NO of J2 on Alarm Termination circuit card
loop circuit is provided between terminals LV-NC and LV-COM of J2 on Alarm
Termination circuit card 423356900 located within the VPS Distribution Cabinet
Assembly during an alarm condition.
6) AC Fail Alarm: A close loop circuit is provided between terminals A/C

FAIL-COM and A/C FAIL-NO of J2/J3 on Alarm Termination circuit card
loop circuit is provided between terminals A/C FAIL-NC and A/C FAIL-COM of J2
on Alarm Termination circuit card 423356900 located within the VPS Distribution
Cabinet Assembly during an alarm condition.

7) High Voltage Alarm 2: A close loop circuit is provided between terminals

HVA2-COM and HVA2-NO of J3 on Alarm Termination circuit card 423356900
located within the VPS Distribution Cabinet Assembly, and an open loop circuit is
provided between terminals HVA2-NC and HVA2-COM of J3 on Alarm

terminals 50% DISCHARGE-COM and 50% DISCHARGE-NO of J3 on Alarm
Assembly, and an open loop circuit is provided between terminals 50%
DISCHARGE-NC and 50% DISCHARGE-COM of J3 on Alarm Termination
circuit card 423356900 located within the VPS Distribution Cabinet Assembly
during an alarm condition.
9) Minor Alarm: A close loop circuit is provided between terminals MN-COM and
MN-NO of J3 on Alarm Termination circuit card 423356900 located within the
terminals MN-NC and MN-COM of J3 on Alarm Termination circuit card
alarm condition.
10) Converter Minor Alarm: not applicable
11) Converter Major Alarm: not applicable

Power System Circuits J1-J4 Power System Circuits J1-J4
TEST/EQ-NC 50% DISCHARGE-NC

50% Battery on
Test/Equalize* TEST/EQ-COM 50% DISCHARGE-COM
Discharge Alarm*
TEST/EQ-NO 50% DISCHARGE-NO
AUD-NO HVA2-NC
High Voltage
Audible Alarm** AUD-COM HVA2-COM
Alarm 2*
AUD-NC HVA2-NO
MJ-NO MN-NC
Minor
Major Alarm** MJ-COM MN-COM
Alarm*
MJ-NC MN-NO
HV-NC CONV MN-NC

High Voltage
HV-COM not applicable CONV MN-COM
Alarm 1*
HV-NO CONV MN-NO
LV-NC CONV MJ-NC

Battery on
LV-COM not applicable CONV MJ-COM
Discharge Alarm*
LV-NO CONV MJ-NO
A/C FAIL-NC
AC Fail Alarm* A/C FAIL-COM
A/C FAIL-NO
TERMINAL BLOCKS J1-J4 ON ALARM TERMINATION CIRCUIT CARD 423356900

LOCATED WITHIN THE VPS DISTRIBUTION CABINET ASSEMBLY
(582120100 LISTS 40 AND 41 ONLY)
Notes
* These relay contacts are deenergized during normal operation, and energized during an alarm
condition.
** These relay contacts are energized during normal operation, and deenergized during an alarm
condition.
All relay contacts are shown with the relays deenergized.

See referenced notes for operating status before making connections.
Figure 3-5K
(J1-J4 on Alarm Termination Circuit Card 423356900)
(582120100 LISTS 40 AND 41 ONLY)

Connections to Terminal Blocks J1-J4 on Alarm

Termination Circuit Card 423356100 Procedure
(582120100 Lists 40 and 41 only):
Refer to Figure 3-4 for connector location, and Figure 3-5L for connector pinouts.
Terminal blocks J1-J4 accept a maximum wire size of 14 gauge, and recommended
torque is 9 in-lbs. Recommended wire size is 22 AWG for loop lengths up to 200' and
18-20 AWG for loop lengths over 200'.
12) Fuse Alarm: A close loop circuit is provided between terminals FUSE-COM and
FUSE-NO of J1 on Alarm Termination circuit card 423356100 located within the
terminals FUSE-NC and FUSE-COM of J1 on Alarm Termination circuit card
alarm condition.
13) Audible Alarm: A close loop circuit is provided between terminals AUD-NC and
AUD-COM of J1 on Alarm Termination circuit card 423356100 located within the
terminals AUD-COM and AUD-NO of J1 on Alarm Termination circuit card
423356100 located within the VPS Distribution Cabinet Assembly during any
alarm condition. These terminals may be factory connected to an audible alarm
circuit.
14) Major Alarm: A close loop circuit is provided between terminals MJ-NC and
MJ-COM of J1/J2 on Alarm Termination circuit card 423356100 located within
the VPS Distribution Cabinet Assembly, and an open loop circuit is provided
between terminals MJ-COM and MJ-NO of J2 on Alarm Termination circuit card
alarm condition.
15) High Voltage Alarm (High Voltage Alarm 1): A close loop circuit is provided
between terminals HV-COM and HV-NO of J2 on Alarm Termination circuit card
loop circuit is provided between terminals HV-NC and HV-COM of J2 on Alarm
16) Low Voltage Alarm (Battery On Discharge Alarm): A close loop circuit is
provided between terminals LV-COM and LV-NO of J2 on Alarm Termination
circuit card 423356100 located within the VPS Distribution Cabinet Assembly,
and an open loop circuit is provided between terminals LV-NC and LV-COM of J2
17) AC Fail Alarm: A close loop circuit is provided between terminals A/C
FAIL-COM and A/C FAIL-NO of J2/J3 on Alarm Termination circuit card
loop circuit is provided between terminals A/C FAIL-NC and A/C FAIL-COM of J2

18) Rectifier Minor Alarm: A close loop circuit is provided between terminals RECT
MN-COM and RECT MN-NO of J3 on Alarm Termination circuit card 423356100
provided between terminals RECT MN-NC and RECT MN-COM of J3 on Alarm
19) Rectifier Major Alarm: A close loop circuit is provided between terminals RECT
MJ-COM and RECT MJ-NO of J3 on Alarm Termination circuit card 423356100
provided between terminals RECT MJ-NC and RECT MJ-COM of J3 on Alarm
20) Minor Alarm: A close loop circuit is provided between terminals MN-COM and
MN-NO of J3 on Alarm Termination circuit card 423356100 located within the
terminals MN-NC and MN-COM of J3 on Alarm Termination circuit card
alarm condition.
21) Converter Minor Alarm: not applicable
22) Converter Major Alarm: not applicable

Power System Circuits J1-J4 Power System Circuits J1-J4
FUSE-NC RECT MN-NC

Fuse Alarm* FUSE-COM Rectifier Minor Alarm* RECT MN-COM
FUSE-NO RECT MN-NO
AUD-NO RECT MJ-NC
Audible Alarm** AUD-COM Rectifier Major Alarm* RECT MJ-COM
AUD-NC RECT MJ-NO
MJ-NO MN-NC
Major Alarm** MJ-COM Minor Alarm* MN-COM
MJ-NC MN-NO
HV-NC CONV MN-NC
High Voltage Alarm* HV-COM not applicable CONV MN-COM
HV-NO CONV MN-NO
LV-NC CONV MJ-NC

not applicable
Low Voltage Alarm* LV-COM CONV MJ-COM
LV-NO CONV MJ-NO
A/C FAIL-NC
AC Fail Alarm* A/C FAIL-COM
A/C FAIL-NO
TERMINAL BLOCKS J1-J4 ON ALARM TERMINATION CIRCUIT CARD 423356100

LOCATED WITHIN THE VPS DISTRIBUTION CABINET ASSEMBLY
(582120100 LISTS 40 AND 41 ONLY)
Notes
* These relay contacts are deenergized during normal operation, and energized during an alarm
condition.
** These relay contacts are energized during normal operation, and deenergized during an alarm
condition.
All relay contacts are shown with the relays deenergized.
Figure 3-5L
(J1-J4 on Alarm Termination Circuit Card 423356100)
(582120100 LISTS 40 AND 41 ONLY)

INTERCONNECTIONS BETWEEN MULTIPLE

VPS PCU SHELVES LOCATED IN THE SAME RACK
Multiple VPS PCU Shelves located in the same rack are interconnected via J11 and J12,
as described below.
These connectors are located on the right side panel of the VPS PCU Shelf. Refer to
Figure 3-3 for connector location and identification, and Figure 3-6 for an interconnection
diagram.
Wire harnesses which terminate in the respective mating connector for J11 and J12 are
factory provided and connected.
The following describes the interconnects required when up to five (5) VPS PCU Shelves
are located in the same rack. Follow the procedure up until the interconnects for as
many shelves that the rack contains are made. These interconnects provide the
necessary connections for proper system operation.
Procedure:
1) Ensure a factory supplied cable connects J12 of the 1st VPS PCU Shelf to J11 of
the 2nd VPS PCU Shelf.
2) Ensure a factory supplied cable connects J12 of the 2nd VPS PCU Shelf to J11
of the 3rd VPS PCU Shelf.
3) Ensure a factory supplied cable connects J12 of the 3rd VPS PCU Shelf to J11 of
the 4th VPS PCU Shelf.
4) Ensure a factory supplied cable connects J12 of the 4th VPS PCU Shelf to J11 of
the 5th VPS PCU Shelf.
5) J12 of the 5th VPS PCU Shelf is to remain unconnected.

Note: Your rack may contain

different quantity of VPS PCU
Shelves from those shown
here.
SPEC. NOS. 588700701 1st

AND 588700801 SHOWN, VPS PCU
OTHER SPEC. NOS. SIMILAR SHELF
2nd
VPS PCU
SHELF
3rd
VPS PCU
SHELF
4th
VPS PCU
SHELF
J11/J12: VPS INTELLIGENCE

INTERCONNECTIONS
5th
Interbay
VPS PCU
J12 OF 1st VPS PCU SHELF TO
SHELF
J11 OF 2nd VPS PCU SHELF.
J12 OF 2nd VPS PCU SHELF TO
J11 OF 3rd VPS PCU SHELF.
J12 OF 3rd VPS PCU SHELF TO
J11 OF 4th VPS PCU SHELF.
J12 OF 4th VPS PCU SHELF TO
J11 OF 5th VPS PCU SHELF.
AND SO FORTH.
Figure 3-6
PCU Shelves Interconnects when Located in Same Rack

INTERCONNECTIONS BETWEEN MULTIPLE

VPS PCU SHELVES LOCATED IN SEPARATE RACKS
VPS PCU Shelves located in the same rack are interconnected as described in the
previous procedure.
Multiple VPS PCU Shelves located in separate racks are interconnected via J8-J10 on
"Connector Assembly" circuit card 500441 located in the main VPS Distribution Cabinet
Assembly, and J11 or J12 located on a PCU Shelf in the rack, as described below.
"Connector Assembly" circuit card 500441 is located within the main VPS Distribution
Cabinet Assembly. This circuit card interconnects up to two additional racks of VPS PCU
Shelves, plus the PCU Shelves contained in the rack with the main VPS Distribution
Cabinet Assembly. Refer to Figure 3-4 for connector location and identification.
Connectors J11 and J12 are located on the right side panel of the VPS PCU Shelf. Refer
to Figure 3-3 for connector location and identification.
Refer to Figure 3-7 for an interconnection diagram.
Wire harnesses which terminate in the respective mating connectors are factory
provided.
Procedure:
Note: A circuit card 500441 is located in each VPS Distribution Cabinet Assembly. Only
make connections to J8, J9, or J10 on circuit card 500441 located in the main
VPS Distribution Cabinet Assembly (the one connected to the MCA).
1) Locate "Connector Assembly" circuit card 500441 within the main VPS
2) Connect the supplied interconnecting cable between one of the connectors J8,
J9, or J10 on "Connector Assembly" circuit card 500441 located within the main
VPS Distribution Cabinet Assembly to J11 or J12 of one of the VPS PCU
Shelves located in a separate rack. Route this cable through the opening
provided in the top of the distribution cabinet. Interconnect up to two additional
racks of VPS PCU Shelves to "Connector Assembly" circuit card 500441 in this
fashion. Note that one of these connectors is factory connected to the PCU
Shelves located in the same rack as the main VPS Distribution Cabinet
Assembly.

VPS INTELLIGENCE
INTERCONNECTIONS
To VPS Intelligence Shelf
J11 OR J12 OF VPS
INTELLIGENCE SHELF TO
J8, J9, OR J10 ON CONNECTOR
ASSEMBLY CIRCUIT CARD
500441
Between Bays
J11 OR J12 OF TOP MOST VPS
PCU SHELF IN RACK TO J8, J9,
OR J10 ON CONNECTOR
ASSEMBLY CIRCUIT CARD
500441
J8 J9 J10 J3
J1 J2
CONNECTOR ASSEMBLY
LOCATED IN MAIN VPS
DISTRIBUTION CABINET
ASSEMBLY
Note: A circuit card 500441 is located in

each VPS Distribution Cabinet
Assembly. Only make connections
to J8, J9, or J10 on circuit card
500441 located in the main VPS
Distribution Cabinet Assembly (the
one connected to the MCA).
Figure 3-7
PCU Shelves Interconnects when Located in Separate Rack and PCU Intelligence Shelf Interconnect

CABLE CONNECTION(S) TO THE MCA INTERFACE OPTION

(if Modem or RS-232/Modem Interface Option furnished)
When the MCA Modem or RS-232/Modem Interface option is installed, the remote
access phone line is connected to the RJ-11 connector located on the right side of the
VPS Intelligence Shelf (labeled "J1, Modem"). Refer to Figure 3-8 for connector location
and identification.
The MCA can be accessed using Vortex WinLink installed on a remote PC.
Procedure:
1) Connect a cable from the RJ-11 connector (J1, Modem) located on the right side
panel of the VPS Intelligence Shelf to a phone line dedicated to this VPS (MCA)
Note: At this time install the ferrite cable clamp supplied with the Modem or
RS-232/Modem option onto the phone line at any convenient location
near the VPS Intelligence Shelf.

FRONT OF VPS MCA INTERFACE OPTION

INTELLIGENCE SHELF EITHER ...
MODEM
(FOR REMOTE ACCESS
SPEC. NO. 588700701 SHOWN, VIA VORTEX WINLINK)
OTHER SPEC. NOS. SIMILAR (PHONE LINE CONNECTOR)
RS-232
VIA VORTEX WINLINK)
(RJ-45 CONNECTOR)
RS-485
(FOR INTERFACE TO SMART
MONITORING SYSTEM SUCH AS
VORTEX SMART OR SMART DGU)
RS-232 (RJ-45 CONNECTOR)
Port RS-232/MODEM
VIA VORTEX WINLINK)
(9-PIN FEMALE D-TYPE CONNECTOR
AND PHONE LINE CONNECTOR)
Modem ETHERNET
Port (FOR LOCAL/REMOTE ACCESS
VIA VORTEX WINLINK)
(RJ-45 CONNECTOR,
RS-232/Modem
LOCATED ON SIDE OF OPTION)
Option
Figure 3-8
MCA Interface Option Connector Locations and Identification


(if RS-485 Interface Option furnished)
When the MCA RS-485 Interface option is installed, a SMART Monitoring System is
connected to the RJ-45 connector located on the right side of the VPS Intelligence Shelf
(labeled "J1, RS-485"). Refer to Figure 3-8 for connector location and identification.
With the RS-485 Interface Assembly installed, maximum cable length is 4000 feet.
CONNECTIONS TO A SMART DGU
Note: These instructions are repeated in the DGU instruction manual.
A cable is connected between the RJ-45 connector (J1, RS-485) located on the VPS
Intelligence Shelf and the RJ-45 connector (J1) located on the DGU/Vortex Interface
Circuit Card installed in the DGU. Refer to Figure 3-8 for location of the RJ-45 connector
(J1, RS-485) on the VPS Intelligence Shelf. Refer to the DGU documentation for location
of the RJ-45 connector (J1) on the DGU circuit card. Refer to the next section for cable
specifications and assembly instructions.
Note: At this time install the ferrite cable clamp supplied with the RS-485 Interface
option onto the cable at any convenient location near the VPS Intelligence Shelf.
SMART Interface Cable Specifications
The VPS is connected to the DGU with a multi-conductor cable that is terminated on
each end with an RJ-45 plug. These plugs mate with the respective RJ-45 connectors
provided on the VPS and on the DGU.
A cable with RJ-45 plugs attached to both ends may be supplied, or a length of cable with
two unconnected RJ-45 plugs may be supplied, as ordered. If required, the installer is to
assemble the cable per the following instructions and per site requirements.
Cable Assembly Procedure
Attach a plug to each end of the cable per Table 3-1, and the following instructions.
1) Trim and strip (0.5 - 0.56 inch) jacketed cable using appropriate, commercially
available tools.
Note: Do not strip insulated wires.
2) Insert the wires completely into the RJ-45 plug. Visually inspect the assembly to
ensure proper routing of the individual conductors. If using the recommended
cable, follow the color scheme shown in Table 3-1. Refer to Figure 3-9 for the
pin-numbering scheme of the RJ-45 plug.
3) Terminate the cable using appropriate crimp tool; AMP Part No. 2-231652-1 with
die set AMP Part No. 853400-1.

From RJ-45 Jack

To RJ-45 Jack
Located on VPS
Located in DGU
(J1 on RS-485
(J1 on
circuit card
Recommended DGU/Vortex
installed on the
Wire Color Interface circuit
side of the
card installed
Intelligence
inside DGU)
Shelf)
Pin Number
Pin Number
White/Blue Stripe 1 1
Blue 2 2
White/Orange Stripe 3 3
Orange 4 4
White/Green Stripe 5 5
Green 6 6
White/Brown Stripe 7 7
Brown 8 8
Table 3-1
SMART Interface Cable Wiring for Use with a SMART DGU
1 8
Rear View Isometric View

Figure 3-9
RJ-45 Plug
CONNECTIONS TO A VORTEX® SMART OR LMS1000
Note: These instructions are repeated in the Vortex SMART and LMS1000 instruction
manual.
A cable is connected between the RJ-45 connector (J1, RS-485) located on the VPS
Intelligence Shelf and the 9-pin female D-type VPS Port jack (VORTEX, RS-485) located
on Vortex SMART or LMS1000. Refer to Figure 3-8 for location of the RJ-45 connector
(J1, RS-485) on the VPS Intelligence Shelf. Refer to the Vortex SMART or LMS1000
documentation for location of the VPS Port jack (VORTEX, RS-485) on Vortex SMART or
LMS1000. Refer to the next section for cable specifications and assembly instructions.

Note: At this time install the ferrite cable clamp supplied with the RS-485 Interface
option onto the cable at any convenient location near the VPS Intelligence Shelf.
SMART Interface Cable Specifications
The VPS is connected to the Vortex SMART or LMS1000 with a multi-conductor cable
that is terminated on one end with a RJ-45 plug, and on the other end with a 9-pin male
D-type plug. These plugs mate with the RJ-45 jack provided on the VPS Intelligence
Shelf and the 9-pin female D-type VPS Port jack provided on Vortex SMART or
LMS1000.
A cable with the appropriate plugs attached to both ends may be supplied, or a length of
cable with two unconnected plugs may be supplied, as ordered. If required, the installer
is to assemble the cable per the following instructions and per site requirements.
Cable Assembly Procedure
Attach a plug to each end of the cable per Table 3-2, and the following instructions.
Attaching RJ-45 Plug
1) Trim and strip (0.5 - 0.56 inch) jacketed cable using appropriate, commercially
available tools.
Note: Do not strip insulated wires.
2) Insert the wires completely into the RJ-45 plug. Visually inspect the assembly to
ensure proper routing of the individual conductors. If using the recommended
cable, follow the color scheme shown in Table 3-2. Refer to Figure 3-9 for the
pin-numbering scheme of the RJ-45 plug.
3) Terminate the cable using appropriate crimp tool, AMP Part No. 2-231652-1 with
die set AMP Part No. 853400-1.
Attaching 9-Pin Male D-Type Plug
1) Trim and strip (0.75 inch) jacketed cable using appropriate, commercially
available tools.
2) Attach the crimp type contacts to the wires of the cable using a crimp tool, AMP
Part No. 90302-1, or 90312-1, or 404494-7. (Strip the wires approximately one
quarter of an inch.) If using the recommended cable, follow the color scheme
shown in Table 3-2.
3) Insert the crimp type contacts (with wires attached) into the plug housing using
an insertion/extraction tool, AMP Part No. 91067-2. A single ended insertion tool
is also available, AMP Part No. 91234-1.
4) Assemble the retaining clips onto the receptacle flanges with the threaded hole
facing toward the wire side of the connector.
Attaching Cable Clamp Assembly
1) A carrier strip with strain-relief gates is packaged with each assembly. Remove
the curved gate and large blank gate from the carrier strip.

2) Insert the curved gate into the cable clamp slot as shown in Figure 3-10. Insert
the large blank gate into the unused slot.
3) Insert the plug into the clamp with the longer row of contacts in the bottom
(portion of cable clamp which is slotted for cable). Position the cable in the strain
relief channel.
4) Position the cable over the curved gate and close the cable clamp.
5) Thread the screws into the holes in the cable clamp and tighten them to complete
the assembly.
From RJ-45 Jack To 9-Pin D-Type

Located on VPS Jack Located on
Vortex SMART or
(J1 on RS-485
LMS1000
circuit card
Recommended
installed on the (VORTEX, RS-485
Wire Color
side of the jack located on
Intelligence outside of
Shelf) cabinet)
Pin Number Pin Number
White/Blue Stripe 1 3
Blue 2 2
White/Orange Stripe 3 -
Orange 4 -
White/Green Stripe 5 -
Green 6 -
White/Brown Stripe 7 -
Brown 8 5
Table 3-2
SMART Interface Cable Wiring for Use with a Vortex® SMART or LMS1000

UNUSED SLOT
CABLE CLAMP ASSEMBLY
CABLE CLAMP SLOT
LARGE BLANK GATE

CURVED GATE
Note: Cable clamp assembly

may be used for 90° mounting
by exchanging BLANK GATE
and CURVE GATE.
PLUG
Figure 3-10
Assembling Cable Clamp Assembly


(if RS-232 or RS-232/Modem Interface Option furnished)
When the MCA RS-232 or RS-232/Modem Interface option is installed, a remote access
PC can be connected to the RJ-45 connector (RS-232 option) or 9-pin female D-Type
connector (RS-232/Modem option) located on the right side of the VPS Intelligence Shelf
(labeled "J1, RS-232"). Refer to Figure 3-8 and 3-11 for connector location and
identification.
With the RS-232 or RS-232/Modem Interface Assembly installed, maximum

recommended cable length is 100 feet.
The MCA can be accessed using Vortex WinLink installed on a remote PC.
Procedure:
1) Connect a cable from the RJ-45 (RS-232 option) or 9-pin female D-Type
(RS-232/Modem option) connector located on the right side panel of the VPS
Intelligence Shelf to a PC running Vortex WinLink.
Note: At this time install the ferrite cable clamp supplied with the RS-232 option
onto the cable at any convenient location near the VPS Intelligence Shelf.
Note that the RS-232/Modem option is furnished with only one ferrite
cable clamp which is to be installed onto the phone line as described
above.
RS-232 Interface Option Only: Refer to Table 3-3 if you are assembling a
cable with an RJ-45 socket on one end and a 9-pin D-type connector on the
other end. An adapter is also available as described in the next section.
Vortex RJ-45 to DB9 Adapter (for RS-232 Interface Option)
An adapter is available from Digi-Key Corp, P/N 046-0001-ND. The DB9F side of the
adapter plugs into the serial port on a PC. The RJ-45 side of the adapter allows a
straight RJ-45 to RJ-45 cable to be used from the adapter to the 486781700 MCA
RS-232 Interface circuit card. The adapter provides pin-pin connections between the
RJ-45 and DB9F sockets located on the adapter as shown in Table 3-3.
RJ-45 DB9-F
COLOR
Socket Socket
1 Blue 2
2 Orange 8
3 Black 3
4 Red 7
5 Green 4
6 Yellow 6
7 Brown 1
8 White 5
Table 3-3
RS-232 Interface Option RJ-45 to 9-Pin D-Type Connector

RS-232 Port
Pin Application
1 --
1 6
2 Transmitted Data (TxD) RS-232 Port 9
(9-Pin Female J1 5
3 Received Data (RxD) Connector)
4 Data Set Ready (/DSR)
5 Signal Ground (GND)
6 Data Terminal Ready (/DTR)
7 Clear to Send (/CTS)*

Modem
8 Request to Send (/RTS)* Port
9 --
* Hardware Handshake Signal RS-232/Modem

(when RTS/CTS Hardware Assembly
Handshake Enabled)
RS-232 Port on RS-232/Modem MCA Interface Assembly
RS-232 Port
8 1 8 Pin Application
1
7 --
Top View
of RJ-45 Jack 1 Transmitted Data (TxD)
3 Received Data (RxD)
5 Data Set Ready (/DSR)
1 8 8 Signal Ground (GND)

Front View
of RJ-45 Jack 6 Data Terminal Ready (/DTR)
4 Clear to Send (/CTS)*

RS-232
Assembly
2 Request to Send (/RTS)*
RS-232 Port on RS-232 MCA Interface Assembly

Figure 3-11
RS-232 and RS-232/Modem Assembly, if installed
Port Locations and RS-232 Port Pinouts


(if Ethernet Interface Option furnished)
Perform the appropriate procedure in "Chapter 4. Installing the PCUs and Initially
Starting VPS" to program the IP parameters into the MCA Ethernet card.
The MCA is connected to the customer's network running TCP/IP via the RJ-45 10BaseT
jack located on the right side of the VPS Intelligence Shelf (labeled "J1, Ethernet"). Refer
to Figure 3-8 for location. Jack pin configuration is a standard Ethernet scheme, twisted
pair.
ALARM, REFERENCE, AND CONTROL INTERCONNECTIONS

BETWEEN VPS INTELLIGENCE SHELF AND VPS DISTRIBUTION
CABINET ASSEMBLY
Alarm, reference, and control interconnections between the VPS Intelligence Shelf and
the VPS Distribution Cabinet Assembly are made via J9 on the VPS Intelligence Shelf
and J2 on "Connector Assembly" circuit card 500441 inside the main VPS Distribution
Cabinet Assembly, and J8 on the VPS Intelligence Shelf and J8 on Alarm Termination
circuit card 423356900 or 423356100 inside the main VPS Distribution Cabinet Assembly
(582120100 Lists 40 and 41 only). These connectors are subminiature D-type
connectors. Refer to Figures 3-3 and 3-4 for connector locations and identifications, and
Figure 3-12 for an interconnection diagram.
Wire harnesses which terminate in the respective mating connectors are factory provided
and connected.
Procedure:
1) Ensure the factory supplied cable is connected from J9 on the VPS Intelligence
Shelf to J2 on "Connector Assembly" circuit card 500441 inside the main VPS
Only make this connections to circuit card 500441 located in the main VPS
Distribution Cabinet Assembly (the one connected to the MCA).
2) Ensure the factory supplied cable is connected from J8 on the VPS Intelligence
Shelf to J8 on Alarm Termination circuit card 423356900 or 423356100 inside the
main VPS Distribution Cabinet Assembly. (582120100 Lists 40 and 41 only.)

ALARM, REFERENCE, AND CONTROL INTERCONNECTIONS

BETWEEN MULTIPLE VPS DISTRIBUTION CABINET
ASSEMBLIES
Alarm, reference, and control interconnections between multiple VPS Distribution Cabinet
Assemblies are made via J1 and J2 on "Connector Assembly" circuit card 500441
located within each VPS Distribution Cabinet Assembly. Refer to Figure 3-4 for
connector locations and identifications. Refer to Figure 3-12 for an interconnection
diagram.
Procedure:
1) Connect the cable from J1 on 500441 installed in the main VPS Distribution
Cabinet Assembly to J2 on 500441 installed in a second VPS Distribution
Cabinet Assembly. Connect another cable from J1 on 500441 installed in the
second VPS Distribution Cabinet Assembly to J2 on 500441 installed in a third
VPS Distribution Cabinet Assembly. Route this cable through the opening
provided in the top of the distribution cabinet.

CABLE PART NO. 100916 CABLE PART NO. 100916
CONNECTOR ASSEMBLY CONNECTOR ASSEMBLY CONNECTOR ASSEMBLY

CIRCUIT CARD (500441) CIRCUIT CARD (500441) CIRCUIT CARD (500441)
LOCATED IN THIRD VPS LOCATED IN SECOND LOCATED IN MAIN VPS
DISTRIBUTION CABINET VPS DISTRIBUTION DISTRIBUTION CABINET
ASSEMBLY CABINET ASSEMBLY ASSEMBLY
J8 J9 J10 J3 J8 J9 J10 J3 J8 J9 J10 J3
J1 J2 J1 J2 J1 J2
CABLE PART NO. 421868200
Figure 3-12
VPS Distribution Cabinet Assemblies Alarm, Reference, and Control Interconnections

LOAD CONNECTIONS
[TO VPS DISTRIBUTION CABINET ASSEMBLY(S)]
Refer to SAG582120100 for recommended lugs and wire sizes. Refer also to drawings
031110100 through 031110300 for additional lug information. These can be accessed
from the CD (Electronic Documentation Package) provided with your system.
Refer to Table 3-4 for lug crimping information.
a) To VPS Modular Distribution Fuseholder/Circuit Breaker Mounting Blocks

(TPA-Type Fuses/LEL1-Type Circuit Breakers): Load conductors and lugs are
connected to the VPS modular distribution fuseholder/circuit breaker mounting
blocks and the respective distribution ground busbar(s) located in a VPS
Distribution Cabinet Assembly. To access these, open the front door of the VPS
Distribution Cabinet Assembly by turning and holding the captive fastener in the
counterclockwise position. Refer to Figure 3-13 for lug mounting location and
identification.
The VPS modular distribution fuseholder/circuit breaker mounting blocks provide

1/4-20 studs and mounting hardware for installation of customer provided two
hole lugs with 5/8 inch centers and 1/4 inch bolt clearance holes. The distribution
ground busbar(s) is provided with 1/4-20 studs for installation of the same type of
customer provided lugs. Customer must provide additional lug mounting
hardware for the distribution ground busbar(s). Maximum size of wire to be
connected to a single position of a VPS modular fuseholder/circuit breaker
mounting block is 2 gauge. When special application crimp lug / strap
combination is used, maximum wire size is as listed in SAG582120100.
When lugs are secured to VPS modular distribution fuseholder/circuit breaker

mounting blocks or distribution ground busbar, recommended torque is 72 in-lbs
when a standard flat washer and lock washer are used.
Note: LOAD A Bus may be arranged with battery disconnect fuse(s)/circuit

breakers. Refer to the CIRCUIT DESIGNATION REFERENCE CARDS
furnished inside the cabinet assembly's front door for location of any
battery disconnect fuse(s)/circuit breakers installed.
b) To TPL-Type Distribution Fuse Mounting Block: Load conductors and lugs

are connected to the distribution fuse mounting block and the respective
distribution ground busbar located in a VPS Distribution Cabinet Assembly. To
access these, open the front door of the VPS Distribution Cabinet Assembly by
turning and holding the captive fastener in the counterclockwise position. Refer
to Figure 3-13 for lug mounting location and identification.
The distribution fuse mounting block provides a busbar with 3/8-16 captive nuts
for installation of customer provided two hole lugs with 1 inch centers and 3/8
inch bolt clearance holes. The distribution ground busbar is provided with 3/8-16
captive nuts for installation of the same type of customer provided lugs.
Customer must provide lug mounting bolts and additional hardware.
When lugs are secured using 3/8 inch bolts, recommended torque is 180 in-lbs
when a Belleville lock washer is used, and 300 in-lbs when a standard flat


c) To GJ/218-Type Distribution Circuit Breaker Mounting Block: Load

conductors and lugs are connected to the distribution circuit breaker mounting
block and the respective distribution ground busbar located in a VPS Distribution
Cabinet Assembly. To access these, open the front door of the VPS Distribution
Cabinet Assembly by turning and holding the captive fastener in the
identification.
The distribution circuit breaker mounting block provides a busbar with 3/8-16
captive nuts for installation of customer provided two hole lugs with 1 inch
centers and 3/8 inch bolt clearance holes. The distribution ground busbar is
provided with 3/8-16 captive nuts for installation of the same type of customer
provided lugs. Customer must provide lug mounting bolts and additional
hardware.

Shunt Connections to GJ/218-Type

Circuit Breakers E/W Internal Shunt
If GJ/218-type circuit breakers with an internal shunt are furnished, connect the circuit
breaker shunt leads as shown in Figure 3-14. Distribution panels are arranged with three
circuit breakers per panel. A sheet of number labels (1, 2, and 3) are supplied with each
circuit breaker. Attach a different number label to each shunt wire pair per panel to
designate panel shunt pair #1, #2, and #3. When breakers are factory installed, shunt
pairs are factory designated per panel as #1 being the bottom-most breaker per panel, #2
is the middle breaker, and #3 is the top-most breaker.

LUG CRIMPING INFORMATION

Crimp Tool Required1
T & B Model TBM12 or TBM15
Crimp Lug Part No. Hydraulic Heads
Die Index/ Die Cat.
Color Key
Code No. Number
1
245342300 Burndy: YAV10-2TC14 - - WT-1300
T & B: 54205
245346700 BLUE 24 15522
Burndy: YA6CL-2TC14
T & B: 54206
245346800 GREY 29 15527
Burndy: YA4CL-2TC14
T & B: 54207
245346900 BROWN 33 15528
Burndy: YA2CL-2TC14
T & B: 54209
245347100 PINK 42H 15508
Burndy: YA25L-2TC38
T & B: 54210
245347200 BLACK 45 15526
Burndy: YA26L-2TC38
T & B: 54211
245347300 ORANGE 50 15530
Burndy: YA27L-2TC38
T & B: 54212
245347400 PURPLE 54H 15511
Burndy: YA28L-2TC38
T & B: 54213
245347500 YELLOW 62 15510
Burndy: YA29L-2TC38
T & B: 54214
245347600 WHITE 66 15534
Burndy: YA30L-2TC38
T & B: 54215
245347700 RED 71H 15514
Burndy: YA31L-2TC38
T & B: 54216
245347800 BLUE 76 15512
Burndy: YA32L-2TC38
T & B: 54218
245347900 BROWN 87H 15506
Burndy: YA34L-2TC38
T & B: 256-30695-257
245348200 BROWN 33 15528
Burndy: YA2CL-2TC38
T & B: 256-30695-255
245350000 GREY 29 15527
Burndy: YA4CL-2TC38
245390200 T & B: 54850BE RED 21 15520
245393500 Burndy: YA25L-4TCG1 PINK 42H 15508
245393600 Burndy: YA26L-4TCG1 BLACK 45 15526
245393700 Burndy: YA27L-4TCG1 ORANGE 50 15530
245393800 Burndy: YA28L-4TCG1 PURPLE 54H 15511
1
The lugs should be crimped to the specifications given in the manufacturer’s instructions
furnished with the crimp tool or lug. For Part No. 245342300 crimp lug, use T & B Model
WT-1300 Shure Stake Hand Crimp Tool.
Table 3-4
Lug Crimping Information

LOAD
CONNECTIONS
LOAD RETURN
CONNECTIONS
GROUND
BUSBAR
F1/ LOAD CIRCUIT BREAKERS/FUSES F24/

CB1 CB24
Figure 3-13 (Detail A)

Typical Load Connections to VPS Modular
Fuseholder/Circuit Breaker Mounting Blocks
(TPA-Type Fuses and/or LEL1-Type Circuit Breakers)
(Single Load Bus)
(VPS Distribution Cabinet Assembly)
SUBSYSTEM LOAD SYSTEM LOAD

CONNECTIONS CONNECTIONS
LOAD RETURN
CONNECTIONS
GROUND
BUSBAR
F1/ F4/ F9/ LOAD (SYSTEM) F24/

CB1 CB4 CB9 CIRCUIT BREAKERS/FUSES CB24
LOAD (SUBSYSTEM)
CIRCUIT BREAKERS/FUSES
Figure 3-13 (Detail B)

Typical Load Connections to VPS Modular
(Dual Load Bus)

LOAD RETURN
CONNECTIONS
LOAD
CONNECTIONS
GROUND LOAD
BUSBAR FUSE
Figure 3-13 (Detail C)

Typical Load Connections to TPL-Type Fuse Mounting Block
LOAD LOAD RETURN

GROUND
BUSBAR
LOAD
CIRCUIT BREAKER(S) LVD
CONTACTOR
Figure 3-13 (Detail D)

Typical Load Connections to GJ/218-Type Circuit Breaker Mounting Block

LOAD BATTERY (LOAD SIDE)

LOAD RETURN
CONNECTIONS
BATTERY
(RETURN SIDE)
GROUND CONNECTIONS.
BUSBAR CONNECT PER
FIGURE 3-15.
F1/ LOAD CIRCUIT F16/ CB CB

CB1 BREAKERS/FUSES CB16 22 24
BATTERY DISCONNECT
CIRCUIT BREAKERS
Figure 3-13 (Detail E)

Typical Load and Battery Connections to VPS Modular
LOAD
CONNECTIONS
LOAD RETURN BATTERY (LOAD SIDE)

BATTERY
(RETURN SIDE)
CONNECTIONS.
GROUND CONNECT PER
BUSBAR FIGURE 3-15.
F1/ F12/
LOAD CIRCUIT CB12 BATTERY
CB1 BREAKERS/FUSES DISCONNECT
FUSE
Figure 3-13 (Detail F)

Typical Load and Battery Connections to VPS Modular
Distribution Fuseholder/Circuit Breaker Mounting Blocks
(TPA-Type Fuses and/or LEL1-Type Circuit Breakers) and
Battery Disconnect TPL-Type Fuse Mounting Block

BATTERY (LOAD SIDE) BATTERY

CONNECTIONS (RETURN SIDE)
CONNECTIONS.
CONNECT PER
FIGURE 3-15.
BATTERY DISCONNECT
CIRCUIT BREAKER(S)
Figure 3-13 (Detail G)
Typical Battery Connections to GJ/218-Type Circuit Breaker Mounting Block

BATTERY (LOAD SIDE)

CONNECTIONS
BATTERY
(RETURN SIDE)
CONNECTIONS.
CONNECT PER
FIGURE 3-15.
BATTERY BATTERY
DISCONNECT DISCONNECT
FUSE FUSE
BATTERY (RETURN SIDE)

CONNECTIONS
BATTERY (LOAD SIDE)

CONNECTIONS
BATTERY
RETURN
BUSBAR
BATTERY
DISCONNECT
FUSE
Figure 3-13 (Detail H)

Typical Battery Connections to TPL-Type Fuse Mounting Block

BATTERY (LOAD SIDE)

CONNECTIONS
BATTERY (RETURN SIDE)
CONNECTIONS
GROUND
BUSBAR
CB1 BATTERY DISCONNECT CB10

CIRCUIT BREAKERS
Figure 3-13 (Detail J)

Typical Battery Connections to VPS Modular

LOAD
CONNECTIONS
LOAD LOAD
FUSE FUSE
LOAD RETURN
CONNECTIONS
GROUND
BUSBAR
TYPICAL LOAD CONNECTIONS TO

TPL-TYPE FUSE MOUNTING BLOCK
Figure 3-13 (Detail K)
Typical Load Connections to TPL-Type Fuse Mounting Block

)
iled 1)
n co dS
nu b el e
(w
he (La
re
4 8" d Wi
Re
WG
Factory 1 8A
FA/CBA
)
Alarm Wiring S2
le d
be
(La 49.9 Ohm
i re
c kW In-Line Resistor
B la (Each Lead)
A WG
18
SHUNT CONNECTIONS
(Terminated in
Stripped Wires)
S1 (Red Wire) to +Shunt

S2 (Black Wire) to -Shunt
Note: Distribution panels

are arranged with three
circuit breakers per panel.
A sheet of number labels
(1, 2, and 3) are supplied
with each circuit breaker.
Attach a different number
label to each shunt wire
pair per panel to designate
panel shunt pair #1, #2, and #3.
When breakers are factory installed,
shunt pairs are factory designated
per panel as #1 being the bottom-most
breaker per panel, #2 is the middle
breaker, and #3 is the top-most breaker.
Figure 3-14
Shunt Wiring to GJ/218-Type Circuit Breakers E/W Internal Shunt

BATTERY CONNECTIONS
[TO VPS DISTRIBUTION CABINET ASSEMBLY(S)]
Danger: Although battery voltage is not hazardously high, the battery can deliver
large amounts of current. Exercise extreme caution not to inadvertently
contact or have any tool inadvertently contact a battery terminal or
exposed wire connected to a battery terminal. Remove watches, rings, or
other jewelry before connecting battery leads.
Refer to SAG582120100 for recommended lugs and wire sizes. Refer also to drawings
031110100 through 031110300 for additional lug information. These can be accessed
from the CD (Electronic Documentation Package) provided with your system.
Refer to Table 3-4 for lug crimping information.
There are three methods of connecting the battery, as determined by the bus
arrangement specified when the system was ordered. Refer to Figures 3-13, 3-15, and
3-16 for lug mounting location and identification.
Procedure:
1) Directly to the Battery Busbar and Battery Ground Busbar (see below if
582120100 List V or W): In this method, battery conductors and lugs are
connected to the battery busbar and battery ground busbar located in a VPS
Distribution Cabinet Assembly. To access these, open the front door of the VPS
Distribution Cabinet Assembly by turning and holding the captive fastener in the
identification.
These busbars are provided with 3/8-16 and 1/4-20 captive nuts for installation of
customer provided two hole lugs with 1 or 5/8 inch centers and 3/8 or 1/4 inch
bolt clearance holes, respectively. Customer must provide lug mounting bolts
and additional hardware.
washer and lock washer are used. When lugs are secured using 1/4 inch bolts,
recommended torque is 60 in-lbs when a Belleville lock washer is used, and 84
in-lbs when a standard flat washer and lock washer are used.
Note: Optional location for battery connections when used with V100ICAB PCU
Shelf located on lower distribution cabinet busbars, as shown in Figure
3-2A.
2) To Internal TPL-Type Battery Disconnect Fuse(s), LEL1-Type Battery

Disconnect VPS Modular Circuit Breakers, or GJ/218-Type Battery
Disconnect Circuit Breaker(s) and Battery Ground Busbar: In this method,
battery conductors and lugs are connected to the battery ground busbar and to
respective battery disconnect fuse or circuit breaker mounting block(s). These
are located in the VPS Distribution Cabinet Assembly. Refer to the CIRCUIT
DESIGNATION REFERENCE CARDS furnished inside the cabinet assembly's
front door for location of any battery disconnect fuse(s) or circuit breakers
installed. To access these, open the front door of the VPS Distribution Cabinet
Assembly by turning and holding the captive fastener in the counterclockwise

position. Refer to Figures 3-14 and 3-15 for lug mounting location and
identification.
The TPL-type fuse mounting block(s) (if furnished) provides a busbar with
3/8-16 captive nuts for installation of customer provided two hole lugs with 1 inch
centers and 3/8 inch bolt clearance holes. Customer must provide lug mounting
bolts and additional hardware. When lugs are secured to a fuse mounting block
busbar using 3/8 inch bolts, recommended torque is 180 in-lbs when a Belleville
lock washer is used, and 300 in-lbs when a standard flat washer and lock washer
are used.
The LEL1-type VPS modular circuit breaker mounting blocks (if furnished)
provide 1/4-20 studs and mounting hardware for installation of customer provided
two hole lugs with 5/8 inch centers and 1/4 inch bolt clearance holes. Maximum
size of wire to be connected to a single position of a VPS modular circuit breaker
mounting block is 2 gauge. When special application crimp lug / strap
combination is used, maximum wire size is as listed in SAG582120100. When
lugs are secured to VPS modular circuit breaker mounting blocks, recommended
torque is 72 in-lbs when a standard flat washer and lock washer are used.
The GJ/218-type circuit breaker mounting block(s) (if furnished) provides a

busbar with 3/8-16 captive nuts for installation of customer provided two hole
lugs with 1 inch centers and 3/8 inch bolt clearance holes. Customer must
provide lug mounting bolts and additional hardware. When lugs are secured to a
circuit breaker mounting block busbar using 3/8 inch bolts, recommended torque
is 180 in-lbs when a Belleville lock washer is used, and 300 in-lbs when a
standard flat washer and lock washer are used.
The battery ground busbar is provided with 3/8-16 and 1/4-20 captive nuts for
installation of customer provided two hole lugs with 1 or 5/8 inch centers and 3/8
or 1/4 inch bolt clearance holes, respectively. Customer must provide lug
mounting bolts and additional hardware. When lugs are secured to the battery
ground busbar using 3/8 inch bolts, recommended torque is 180 in-lbs when a
Belleville lock washer is used, and 300 in-lbs when a standard flat washer and
lock washer are used. When lugs are secured to the battery ground busbar
using 1/4 inch bolts, recommended torque is 60 in-lbs when a Belleville lock
washer is used, and 84 in-lbs when a standard flat washer and lock washer are
used.
Note: 582120100 List EE also provides a battery ground busbar tied to the main
battery ground busbar.
3) To Internal Battery Disconnect Contactor and Battery Ground Busbar

(582120100 Lists V and W only): In this method, battery conductors and lugs
are connected to the battery busbar (the busbar connected to the customer side
of the battery disconnect contactor) and the battery ground busbar located in a
VPS Distribution Cabinet Assembly. To access these, open the front door of the
VPS Distribution Cabinet Assembly by turning and holding the captive fastener in
the counterclockwise position. Refer to Figure 3-16 for lug mounting location and
identification.
The battery busbar is provided with 3/8-16 captive nuts for installation of
customer provided two hole lugs with 1 inch centers and 3/8 inch bolt clearance
holes.

The battery ground busbar is provided with 3/8-16 and 1/4-20 captive nuts for
installation of customer provided two hole lugs with 1 or 5/8 inch centers and 3/8
or 1/4 inch bolt clearance holes, respectively.
Customer must provide lug mounting bolts and additional hardware.
washer and lock washer are used. When lugs are secured using 1/4 inch bolts,
recommended torque is 60 in-lbs when a Belleville lock washer is used, and 84
in-lbs when a standard flat washer and lock washer are used.

3/8-16 CAPTIVE NUT, 12 PLACES

(CUSTOMER MUST SUPPLY LUG
BOLTS AND ADDITIONAL HARDWARE)

(CUSTOMER MUST SUPPLY LUG TOP OF VPS DISTRIBUTION
BOLTS AND ADDITIONAL HARDWARE) CABINET ASSEMBLY
0.625
Central 2.000
0.750
Office
Ground 0.625 2.000
1.000
0.625
BATTERY 0.625 0.750 BATTERY

(RETURN SIDE) (LOAD SIDE)
BUSBAR 0.750 0.750 BUSBAR
0.625 FRONT VIEW
GND RTN SUPPLY

+48V -48V
Figure 3-15
Battery Connections when Battery Disconnect Fuse(s)/Circuit Breakers are NOT Provided
(VPS Distribution Cabinet Assembly) (See Figure 3-16 if 582120100 List V or W)



0.625
Central
0.750
Office
Ground 0.625
1.000
0.625
BATTERY 0.625
(RETURN SIDE) FRONT VIEW
BUSBAR 0.750
0.625
GND RTN
UPPER SECTION OF VPS
+48V DISTRIBUTION CABINET ASSEMBLY
BATTERY
SUPPLY 1.250 (LOAD SIDE)
1.250 BUSBAR
-48V
1.000
LOWER SECTION OF VPS

DISTRIBUTION CABINET ASSEMBLY FRONT VIEW
Figure 3-16
Battery Connections For 582120100 Lists V and W

CHAPTER 4
INSTALLING THE PCUs AND
INITIALLY STARTING VPS
TABLE OF CONTENTS
Installing the PCUs .......................................................................................................... 4-2
Spec. Nos. 588700701, 588700801, 588703600, and 588703700 .......................... 4-2
Spec. Nos. 588701300 and 588701400 ................................................................... 4-2
Initially Starting, Configuring, and Checking System Operation...................................... 4-2
Observe the Following Admonishment ..................................................................... 4-2
Controls and Indicators ............................................................................................. 4-2
Initial Startup Preparation ......................................................................................... 4-2
Initially Starting the System....................................................................................... 4-3
MCA Initialization ...................................................................................................... 4-3
Initially Connecting Low Voltage Disconnect Circuits (if furnished).......................... 4-8
Configuring the System............................................................................................. 4-9
Setting Up the MCA Ethernet Option, if installed.................................................... 4-12
Checking Meter Operation ...................................................................................... 4-16
Checking Adjustment and Calibration Values......................................................... 4-18
Checking MCA Audible Alarm and MCA Audible Alarm Cutoff (if available).......... 4-18
Checking Manual Test/Equalize and Manually Initiated Timed Test/Equalize ....... 4-19
Checking Remote Test/Equalize............................................................................. 4-22
Checking Remote High Voltage Shutdown............................................................. 4-22
Checking Emergency Shutdown and Fire Alarm Disconnect ................................. 4-23
Checking Remote On/Off (TR) (if RS-485 Interface Option is installed) ................ 4-23
Checking High Voltage Shutdown .......................................................................... 4-24
Checking AC Fail Alarm.......................................................................................... 4-25
Checking PCU Fail Alarm ....................................................................................... 4-26
Checking Open Sense Alarm.................................................................................. 4-27
Checking Fuse Alarm/Circuit Breaker Alarm .......................................................... 4-28
Checking System High Voltage Alarm 1................................................................. 4-30
Checking System High Voltage Alarm 2................................................................. 4-32
Checking System Battery On Discharge Alarm ...................................................... 4-33
Checking System 50% Battery On Discharge (Very Low Voltage) Alarm .............. 4-34
Checking System Current Alarm............................................................................. 4-36
Checking Subsystem (if subsystem installed) High Voltage Alarm ........................ 4-37
Checking Subsystem (if subsystem installed) Low Voltage Alarm ......................... 4-39
Checking Subsystem (if subsystem installed) Current Alarm................................. 4-40
Checking Low Voltage Disconnect (if furnished) .................................................... 4-41
Checking System Status......................................................................................... 4-45
Final Step ................................................................................................................ 4-45
Chapter 4. Installing the PCUs and Initially Starting VPS Page 4-1
INSTALLING THE PCUs

Spec. Nos. 588700701, 588700801, 588703600, and 588703700
Note: The OUTPUT BREAKER has a mechanical interlock that prevents a PCU from
being plugged into a cabinet with the circuit breaker in the "on" position.
Procedure:
2) Install the PCUs into the shelf, and secure by tightening the captive fasteners on
the front of each.
3) Verify that all PCU handles are in the down position.
Spec. Nos. 588701300 and 588701400

Procedure:
2) Pivot the hinged panel containing the PCU mounting position captive fasteners
down. Install the PCUs into the shelf. Pivot the hinged panel containing the
captive fasteners up. For each PCU installed, tighten the respective captive
fastener located on the hinged panel to secure the PCU to the shelf.
INITIALLY STARTING, CONFIGURING,

AND CHECKING SYSTEM OPERATION
Note: A Battery Thermal Runaway Management System may be furnished. For an
initial startup and checkout procedure, refer to the Battery Thermal Runaway
Management System instructions (Section 5593), provided in this manual.
Observe the Following Admonishment
Caution: Performing various steps in the following procedures may cause a

service interruption and/or result in the extension of alarms. Notify any
appropriate personnel before starting this procedure. Also notify this
personnel when this procedure is completed.
Controls and Indicators

Refer to "Chapter 2. Controls and Indicators" of the separate USER MANUAL for control
and indicator locations. The USER MANUAL can be accessed via the Electronic
Documentation Package provided on the CD shipped with your system.
Initial Startup Preparation

Ensure that the Standby/Operate switch on each PCU is placed to the "standby" position.
Page 4-2 Chapter 4. Installing the PCUs and Initially Starting VPS
Ensure that the OUTPUT BREAKER on each PCU is placed to the 0 "off" position.
Ensure that system wiring options are appropriately made.
Ensure that all electrical connections were performed as previously described.
Ensure that all blocks for Chapters 1-3 in the "Installation Acceptance Checklist", located
at the beginning of Chapter 1, have been checked.
Initially Starting the System

Apply AC input power to the system by closing the external AC disconnects or protective
devices that supply power to the VPS Intelligence and Expansion Shelf(s).
Open the VPS Intelligence and Expansion Shelf(s) front door by turning and holding the
On each PCU, place first the Standby/Operate switch to the I "operate" position, then the
OUTPUT BREAKER to the I "on" position.
If furnished, open the VPS Distribution Cabinet Assembly(s) front door by turning and
holding the captive fastener in the counterclockwise position. Place each distribution
circuit breaker (if furnished) to the ON position.
MCA Initialization
Whenever a system is initially started (or the MCA has been replaced), the MCA
performs an initialization routine. This routine is described below.
Initialization Routine:
Note: Follow step 1A or 1B; as determined by what is being displayed.
1A) If the MCA was previously initialized, when power is applied to the system, the
MCA briefly displays the MCA Configuration Spec. No. and software version
number and then establishes communications with each PCU.
Note: After power-up, you can also view the MCA Configuration Spec. No. and
software version number by following the MCA Menu Tree provided in this
manual.
Note: After power-up, you can change the MCA Configuration Spec. No. by
referring to the MCA Replacement procedure in the troubleshooting
chapter of the separate User Manual.
During this period "INITIALIZING..." is displayed along with the maximum

remaining initialization time in seconds.
Note: Follow step 2A, 2B, 2C, or 2D; as determined by what is being displayed.
2A) If the MCA detects that it is configured for proper voltage operation consistent
with the PCUs (e.g. set for 48V operation and 48V PCUs detected), the MCA
then compares the output capacities (amps) and serial numbers of all PCUs with
what it has stored in memory. If any PCU capacity does not match the value
stored or if none of the serial numbers match, the MCA displays "SET ##V
DEFAULTS".
Note: If this system was factory set with customer specified settings that are
different than the defaults listed in the System Application Guide or Power
Data Sheet, do not reset all stored variables to factory defaults. Instead,
see "Start the System with the MCA's Existing Setpoints Procedure"
below.
Caution: If the system has a Temperature Compensation Module installed,

use the "SET ##V DEFAULTS Procedure" below to set the
"TC CAL =" value. Failure to set the "TC CAL =" value will result
in the system going into High Voltage Shutdown when the
system is started.
SET ##V DEFAULTS Procedure: To reset all stored variables to factory

defaults, press and release the ALARM CUTOFF and FUNCTION SET
ENTER pushbuttons simultaneously. At the "ARE YOU SURE? + -" prompt,
press the FUNCTION SET YES (+) pushbutton. The MCA displays
"INITIALIZING..." along with the maximum remaining initialization time in
seconds while it is resetting the variables, followed by "CHECK
SETPOINTS".
CHECK SETPOINTS Procedure: As you press the FUNCTION

SELECT UP and DOWN arrow pushbuttons, each value listed later in
this procedure under "CHECK SETPOINTS Adjustable Values" is
displayed. Determine if the value displayed is correct for the
application. To change the setting of the currently displayed entry,
press and release the ALARM CUTOFF and FUNCTION SET ENTER
pushbuttons simultaneously. The portion of the display before the equal
sign (=) flashes. Use the FUNCTION SET YES (+) or NO (-) pushbutton
to increase or decrease, respectively, the setting. Press the FUNCTION
SET ENTER pushbutton. At the "ARE YOU SURE? + -" prompt, press
the FUNCTION SET YES (+) pushbutton to store the new value, or the
FUNCTION SET NO (-) pushbutton to cancel this operation without
changing the setting. Display the next or previous entry using the
FUNCTION SELECT UP or DOWN arrow pushbutton. Repeat this
procedure for each entry presented.
System Startup: When all the adjustable values have been properly
set, press the FUNCTION SELECT DOWN arrow pushbutton until
"START THE SYSTEM" is displayed. Press and release the ALARM
CUTOFF and FUNCTION SET ENTER pushbuttons simultaneously. At
the "ARE YOU SURE? + -" prompt, press the FUNCTION SET YES (+)
pushbutton. The MCA briefly displays " INITIALIZING..." along with the
maximum remaining initialization time in seconds while it is starting the
system.
Start the System with the MCA's Existing Setpoints Procedure: To start
the system with the MCA's existing setpoints, press and release the ALARM
CUTOFF and FUNCTION SET ENTER pushbuttons simultaneously. At the
"ARE YOU SURE? + -" prompt, press the FUNCTION SET NO (-)
pushbutton. The MCA displays "CHECK SETPOINTS" during and after
system startup. Press the FUNCTION SELECT UP or DOWN pushbutton to
move to the "System Adjustment Menu".
Caution: If the system has a Temperature Compensation Module

installed and is started without setting the "TC CAL =" value,
the system goes into High Voltage Shutdown. Restart the
system as described in the "Operating Procedures" chapter
of the separate User Manual.
2B) If the MCA detects that it is configured for voltage operation not consistent with
the PCUs (e.g. set for 24V operation and 48V PCUs detected, or set for 48V
operation and 24V PCUs are detected), the MCA displays "MUST SET
SYS=##V".
MUST SET SYS =##V Procedure: Press and release the ALARM CUTOFF
and FUNCTION SET ENTER pushbuttons simultaneously. At the "ARE
YOU SURE? + -" prompt, press the FUNCTION SET YES (+) pushbutton.
The MCA displays "INITIALIZING..." along with the maximum remaining
initialization time in seconds while it reconfigures itself for proper voltage
operation, and then displays "CHECK SETPOINTS".

displayed. Determine if the value displayed is correct for the
application. To change the setting of the currently displayed entry,
press and release the ALARM CUTOFF and FUNCTION SET ENTER
pushbutton. The MCA briefly displays " INITIALIZING..." along with the
system.
2C) If some serial numbers match, MCA starts the system using the MCA's existing
setpoints. The MCA displays "CHECK SETPOINTS" during and after system
startup. Press the FUNCTION SELECT UP or DOWN pushbutton to move to the
"System Adjustment Menu".
2D) If all serial numbers match, the MCA starts the system using its existing
setpoints. After the system is started, the MCA displays "SYSTEM OK" or "##
ALARMS ACTIVE".
1B) If the MCA was never initialized, the MCA displays "MUST SET SPEC NO.".
MUST SET SPEC NO. Procedure: Press and release the FUNCTION
SELECT UP and DOWN arrow pushbuttons until the proper SPEC. NO. and
VOLTAGE (MCA Configuration) are shown. Press and release the ALARM
CUTOFF and FUNCTION SET ENTER pushbuttons simultaneously. At the
"ARE YOU SURE? + -" prompt, press the FUNCTION SET YES (+)
pushbutton. The MCA displays “CHANGING SPEC” then "INITIALIZING..."
along with the maximum remaining initialization time in seconds while it
reconfigures itself for proper operation, and then displays "CHECK
SETPOINTS".
Note: Selecting an MCA Configuration (Spec. No.) or system voltage not

intended for your system will alter system performance, and is not
recommended. Refer to the System Application Guide (SAG) or
Power Data Sheet (PD) to determine the proper MCA Configuration
(Spec. No.) and system voltage.

displayed. To change the setting of the currently displayed entry, press
and release the ALARM CUTOFF and FUNCTION SET ENTER
pushbutton. The MCA briefly displays "INITIALIZING..." along with the
system.
Note: After power-up, you can change the MCA Configuration Spec. No. by
referring to the MCA Replacement procedure in the troubleshooting
chapter of the separate User Manual.
CHECK SETPOINTS Adjustable Values:
1) FLOAT = ##.##V ##.##V=float voltage setting for all PCUs
2) TEST/EQ = ##.##V ##.##V=test equalize voltage setting for all PCUs
3) SET HVS = ##.##V ##.##V=high voltage shutdown setting for all PCUs
4) CURRLIM = #####A ####A=system current limit setting, current limit

circuit on all PCUs are automatically adjusted to
ensure system current does not exceed this value.
CURRLIM = #####MAX #####MAX = the sum of the maximum capabilities of

all PCUs installed in the system
5) SYS HV1 = ##.##V ##.##V=system high voltage alarm 1 setting
6) SYS HV2 = ##.##V ##.##V=system high voltage alarm 2 setting
7) SYS BOD = ##.##V ##.##V=system battery on discharge alarm setting
8) SYS 50% (VERYLOVOLT)= ##.##V ##.##V=system 50% battery on

discharge (very low voltage) alarm
setting
9) SYSCURR = #####A ####A=system current alarm setting
10) SUB HV = ##.##V ##.##V=subsystem high voltage alarm setting
11) SUB LV = ##.##V ##.##V=subsystem low voltage alarm setting
12) SUBCURR = #####A ####A=subsystem current alarm setting
13) LVD ** = ##.#V LVD**=number assigned to the low voltage

disconnect circuit detected, each low voltage
disconnect circuit detected in the system is
displayed separately
##.#V=respective low voltage disconnect circuit

"disconnect" setting
14) LV RECON = ##.#V ##.#V=reconnect setting for all low voltage

MANUAL RECONNECT disconnect circuits detected, or manual reconnect
15) TC CAL = ##.##V ##.##V=calibration voltage value written on

ANALOG TC OFF battery charge temperature compensation
TempCmp Hardware module, or off
Caution: Failure to set the "TC CAL =" value when a Temperature
Compensation Module is installed will result in the system going
into high voltage shutdown when the system is started.
16) DIGITAL TC OFF digital temperature compensation off, or

SLOPE = .###V/ºC slope parameter setting
TempCmp Hardware
17) MAX W/T = ##.##V ##.##V = maximum voltage with temperature

compensation setting
18) MIN W/T = ##.##V ##.##V = minimum voltage with temperature

compensation setting
19) HI TEMP 1 = ###ºC ###ºC = high temperature 1 alarm setting

HI TEMP 1 IS OFF high temperature 1 alarm off
(if TXM installed, each temperature probe has an
associated alarm)
20) LO TEMP 1 = ###ºC ###ºC = low temperature 1 alarm setting

LO TEMP 1 IS OFF low temperature 1 alarm off
(if TXM installed, each temperature probe has an
associated alarm)
21) ***A PLACES = ## ***A=amperage of each type of PCU, each type of

PCU is displayed separately
##=number of total (filled and empty) mounting

positions available for this amperage PCU
22) START THE SYSTEM Press and release the ALARM CUTOFF and
FUNCTION SET ENTER pushbuttons
simultaneously. At the "ARE YOU SURE? + -"
prompt, press the FUNCTION SET YES (+)
pushbutton to start system.
Press the FUNCTION SET NO (-) pushbutton to go

back and change more setpoints before starting the
system. Use the FUNCTION SELECT UP and
DOWN arrow pushbuttons to scroll through the list of
adjustable values as previously described.
Initially Connecting Low Voltage Disconnect Circuits (if furnished)

If the low voltage disconnect circuit(s) (if furnished) is set for manual reconnect, the
battery and system output have to be initially connected to the controlled load(s).
(Battery voltage must be above the upper setting of the low voltage disconnect circuit.) If
there are active low voltage disconnect alarms, perform the following procedure to initially
connect battery and system output to the controlled load(s).
Procedure:
1) Refer to "Chapter 2. Controls and Indicators" of the separate USER MANUAL for
control and indicator locations.
2) With "## ALARMS ACTIVE" being displayed on the MCA Interface Pad, press
and release the FUNCTION SET ENTER pushbutton.
3) Press and release the FUNCTION SELECT DOWN arrow pushbutton to display
"ALARM LVD ACTIVE".
4) Press and release the FUNCTION SET ENTER pushbutton.
5) Repeatedly press and release the FUNCTION SELECT DOWN arrow

pushbutton until the low voltage disconnect circuit to be reconnected is displayed
("RECONNECT LVD**", **=the designation of the low voltage disconnect circuit).
6) To reconnect the low voltage disconnect circuit being displayed, press and
release the ALARM CUTOFF and FUNCTION SET ENTER pushbuttons
simultaneously.
7) "ARE YOU SURE? + -" is displayed. Press and release the FUNCTION SET
YES (+) pushbutton. The low voltage disconnect circuit reconnects.
8) If the system contains additional low voltage disconnect circuits, separately

reconnect these by repeating steps 5) through 7).
9) When done, press and release the FUNCTION SET YES (+) and NO (-)
pushbuttons simultaneously. You are returned to the beginning of the MCA
menu tree.
Configuring the System

Procedure:
2) With "SYSTEM OK" being displayed on the MCA Interface Pad, press and
release the FUNCTION SET ENTER pushbutton.

pushbutton until "CONFIGURE MENU" is displayed.
5) If the MCA Initialization procedure was performed, go to step 15). If not (or if you
want to verify the inventory), proceed with step 6).
6) "VERIFY INVENTORY" is displayed. Press and release the FUNCTION SET

ENTER pushbutton.

pushbutton until "VACANT ****A = ##" is displayed. (****A is the amperage of
the PCU)
8) Press and release the ALARM CUTOFF and FUNCTION SET ENTER
pushbuttons simultaneously. "****A PLACES = ##" is displayed, ****A is the
amperage of the PCU. Portion of the display flashes.
9) Press the FUNCTION SET YES (+) or NO (-) pushbutton until the value
displayed equals the total (filled and empty) number of available mounting
positions in the system for this amperage of PCU, then release the pushbutton.
YES (+) pushbutton. The display stops flashing.
"VACANT ****A = ##". Repeat steps 8) through 11) for any other amperage
PCUs available positions.
15) Press and release the FUNCTION SELECT DOWN arrow pushbutton until
"SHARE ALARM OFF" or "SHARE ALARM ON" is displayed. This is the current
setting for this feature. To toggle this setting, perform steps 16) and 17). To
keep this setting, proceed with step 18).
16) To toggle this setting, press and release the ALARM CUTOFF and FUNCTION
SET ENTER pushbuttons simultaneously.
YES (+) pushbutton.
"DISPLAY ROLL OFF" or "DISPLAY ROLL ON" is displayed. This is the current
setting for this feature. To toggle this setting, perform steps 19) and 20). To
keep this setting, proceed with step 21).
Note: For Initial VPS Startup and Checkout, "DISPLAY ROLL OFF" is preferred.
YES (+) pushbutton.
pushbutton until "LO SPEED FAN OFF" or "LO SPEED FAN ON" is displayed.
This is the current setting for this feature. To toggle this setting, perform steps
22) and 23). To keep this setting, proceed with step 24) or 29).
YES (+) pushbutton.
Note: Do not perform steps 24) through 28) if the system is not equipped with
external MCA Audible Alarm relay contacts.
"NAG MINUTES = ##" or "AUDIBLE NAG OFF".
pushbuttons simultaneously. The "NAG MINUTES =" portion of the display
flashes.
displayed equals the desired MCA audible alarm cutoff reset time period or
"AUDIBLE NAG OFF", then release the pushbutton.
"TEST/EQ HRS = ##".
pushbuttons simultaneously. The "TEST/EQ HRS =" portion of the display
flashes.
displayed equals the desired timed test/equalize period.
Note: To disable the manually initiated timed test/equalize feature, press the
FUNCTION SET YES (+) pushbutton until the value goes above 99.
"TEST/EQ MAN STOP" is then displayed.
"AUTO EQ MUL = ##" or "AUTO EQ DISABLED".
Note: For Initial VPS Startup and Checkout, "AUTO EQ DISABLED" is

preferred.
Note: If "AUTO EQ MUL = ##" is displayed, the system is already set for
Automatic Equalize. In this case, you can proceed with steps 35) through
38) to change the current setting, or proceed with step 39) if no changes
are required.
Note: If "END AUTO ##.##HR" is displayed, the system is already set for
Automatic Equalize, and an Automatic Equalize is in progress. In this
case, you can proceed with steps 35) through 38) to cancel the Automatic
Equalize in progress and change the current setting, or proceed with step
39) to proceed with the Automatic Equalize in progress and make no
changes.
pushbuttons simultaneously. The "AUTO EQ MUL =" portion of the display
flashes.
36) Press the FUNCTION SET YES (+) or NO (-) pushbutton until the desired value
is displayed, then release the pushbutton. Note that as you scroll below 1,
"AUTO EQ DISABLED" is displayed. Scroll back up to redisplay "AUTO EQ MUL
=".
"RELAYTEST = ###SEC".
pushbuttons simultaneously. The "RELAYTEST =" portion of the display flashes.
displayed equals the desired timed period for the Alarm Relay Test feature.
44) Press and release the FUNCTION SET YES (+) and NO (-) pushbuttons
simultaneously, to return to the beginning of the MCA menu tree.
Setting Up the MCA Ethernet Option, if installed

This procedure is for setting the MCA Ethernet card's IP parameters. It requires that you
temporarily change the IP setup on your computer (PC).
Note: Windows 98 or later required to setup network connection.
Procedure:
Step 1: Record your PC's Network Settings

Record your current network settings for the computer you will be using to set the
MCA Ethernet card's IP parameters. You will use these values in step 4.
Step 2: Change your PC's Network Settings

Change your computer's IP parameters to talk to the MCA Ethernet card using
the card's default parameters.
a) 192.168.1.1, set your computer to 192.168.1.2 (IP Address).

b) 255.255.255.0, set your computer to the same (Subnet Mask).
c) 192.168.1.1, set your computer to the same (Gateway).
Step 3: Change the MCA Ethernet Card's Network Settings

Connect the MCA Ethernet card into your company's network. Use Internet
Explorer to change the default MCA Ethernet card IP parameters to the
parameters issued by your IT department.
If your PC cannot access the Vortex setup Web page, it may be necessary to
bypass your company network by using a "cross-over" cable connected directly
between your PC and the MCA Ethernet card.
Step 4: Reset your PC's Network Settings

Reset your computer's IP parameters back to their original values noted in step
1. If using a cross-over cable, first reconnect your computer to your company's
network and connect the MCA Ethernet card to your company's network.
Step 5: Access the Vortex Power Plant over the Company Network
Talk to the MCA Ethernet card over your company's network using WinLink.
Install WinLink, create an MCA entry, select the MCA and click-on the "Connect
to MCA" toolbar button.
Expanded Procedure:
Step 1: Record your PC's Network Settings
1) Open the Control Panel on your computer.
2) Select Network Connections.
3) Select Local Area Connection.
4) Select Properties.
5) Highlight Internet Protocol (TCP/IP).
7) Record the current settings, these may be specific parameters or your computer
may be set to automatically obtained these parameters from your company's
network.
Obtained IP Address Automatically __________________

or
Use the following…
IP Address: __________________
Subnet Mask: __________________
Default Gateway: __________________
8) Select Cancel.
Step 2: Change your PC's Network Settings
7) Select "Use the following IP Address".
8) Enter the following.
a) 192.168.1.2, as the IP Address.

b) 255.255.255.0, as the Subnet Mask.
c) 192.168.1.1, as the default Gateway.
9) Select OK. Note that you may have to reboot your computer for the settings to
take effect. Follow any instructions you see on the screen.
Step 3: Change the MCA Ethernet Card's Network Settings
1) Connect the MCA Ethernet card into your company's network.
2) Power up the MCA, if not already powered.
3) This step requires Java™ plug-in version 1.4.2.04, or better. This can be
downloaded from Sun's website (www.sun.com) or installed from the provided
CD.
Go to Internet Explorer and type 192.168.1.1 the address bar. Then press
ENTER. A Java application downloads into your computer. This may take a
minute or two. The Java application starts
You may have to change Internet Explorer options to do this. Go to

Tools/Internet Options/LAN Settings, then temporarily disable the proxy server.
Another option is to select Bypass Proxy Server for local addresses and add
192.168.* under Advanced.
If the wrong version of Java is detected on your computer, load it from the CD
provided with the MCA Ethernet kit, and then repeat this step.
If your PC cannot access the Vortex setup Web page, it may be necessary to
bypass your company network by using a "cross-over" cable connected directly
between your PC and the MCA Ethernet card. Repeat this step if necessary.
4) Go to the Network section (select Network in left pane) and change the MCA
Ethernet card's IP parameters (in right pane) to the values issued by your IT
department. VERIFY WHAT YOU HAVE TYPED, IF IT IS ENTERED
INCORRECTLY YOU MAY NOT BE ABLE TO COMMUNICATE WITH THE
MCA ETHERNET CARD.
5) Click on the SAVE button.
6) Go to the Reboot section (select Reboot in left pane).
7) Press Reboot (in right pane).
8) Select Yes Reboot Now.
Step 4: Reset your PC's Network Settings
1) If using a cross-over cable, reconnect your computer to your company's network

and connect the MCA Ethernet card to your company's network.
8) Set the IP parameters to the original settings recorded at the beginning of this
document in step 1.
Step 5: Access the Vortex Power Plant over the Company Network
1) Add a new MCA in WinLink.
2) Set the TCP/IP parameters for this entry.

Set the IP address to the address issued by your IT department.
Set the Port to 2001.
3) You can now communicate with the power system over your company's network.
Notes
Provided on the CD furnished with the kit is a program, DGDCPROG /DISCOVER, that
tests the communication path between your computer and the MCA Ethernet card. It
essentially searches for devices on the network and lists their IP addresses.
Checking Meter Operation

Procedure:
3) "MEASUREMENT MENU" is displayed. Press and release the FUNCTION SET

ENTER pushbutton.
d) Requirement: System output voltage is displayed ("SYSTEM ##.##VDC").
"SYS LOAD ####A".
a) Requirement: Total system load current is displayed.
a) Requirement: Load current through the first system load shunt is displayed
("SYS LOAD** ####A").

pushbutton to display individual load currents through the remaining system load
shunts (if furnished and connected to the MCA).
a) Requirement: As the FUNCTION SELECT DOWN arrow pushbutton is

pressed and released, load currents through the remaining system load
shunts are displayed. When all system shunts are cycled through,
"MEASUREMENT MENU" is displayed.
7) If "MEASUREMENT MENU" is not displayed, repeatedly press and release the

FUNCTION SELECT DOWN arrow pushbutton until it is.
9) Press and release the FUNCTION SELECT DOWN arrow pushbutton until “PCU
LOAD ####A” is displayed.
a) Requirement: Total PCU load current is displayed.
a) Requirement: Load current of the first PCU is displayed ("PCU** LOAD

####A").
pushbutton to display individual load currents of the remaining PCUs.

pressed and released, load currents of the remaining PCUs are displayed.
When all PCUs are cycled through, "MEASUREMENT MENU" is displayed.
12) If "MEASUREMENT MENU" is not displayed, repeatedly press and release the
FUNCTION SELECT DOWN arrow pushbutton until it is.
“SUBSYS ##.##VDC” (if subsystem installed) is displayed.
a) Requirement: Subsystem output voltage is displayed.
“SUB LOAD ####A” (if subsystem installed).
a) Requirement: Total subsystem load current is displayed.
b) Requirement: Load current through the first subsystem load shunt is

displayed ("SUB LOAD** ####A") (if subsystem installed).
pushbutton to display individual load currents through the remaining subsystem
load shunts (if subsystem installed).

pressed and released, currents through the remaining subsystem load
shunts are displayed. When all subsystem shunts are cycled through,
"MEASUREMENT MENU" is displayed.
Checking Adjustment and Calibration Values

Procedure:
1) Refer to the "Adjusting and Calibrating VPS" chapter of the separate USER
MANUAL, and perform the adjustment and calibration procedures detailed to
check the value of all customer adjustable system circuits and the calibration
settings.
Note: If the MCA Initialization procedure was performed, all adjustments were
checked at that time.
Note: You may skip the adjustment procedures for the alarms and low voltage
disconnect circuits. They will be checked and adjusted later in this
procedure.
Note: If TXM (multiple probe concentrator module) is installed, set the

'temperature compensation source' per "Chapter 5. Adjusting and
Calibrating VPS" of the separate USER INSTRUCTIONS.
2) When done, come back and finish this procedure.
Checking MCA Audible Alarm and MCA Audible Alarm Cutoff (if available)
Procedure:
2) Place the Standby/Operate switch on a PCU installed in the system to the

"standby" position.
a) Requirement: External MCA audible alarm sounds.
b) Requirement: Other alarms activate. Disregard them here. They will be

confirmed in a later check.
3) Press and release the ALARM CUTOFF pushbutton.
a) Requirement: External MCA audible alarm silences.
b) Requirement: MCA "ALARM CUTOFF" indicator goes yellow.
4) Wait the pre-programmed MCA audible alarm cutoff reset time interval.
a) Requirement: External MCA audible alarm again sounds.
b) Requirement: MCA "ALARM CUTOFF" indicator goes out.
5) Return the Standby/Operate switch on the PCU to the I "operate" position.
a) Requirement: External MCA audible alarm silences.
Checking Manual Test/Equalize

and Manually Initiated Timed Test/Equalize
Procedure:


pushbutton until "TEST/EQ HRS = ##" or "TEST/EQ MAN STOP" is displayed. If
"TEST/EQ HRS = ##" is displayed, perform steps 6) through 10). If "TEST/EQ
MAN STOP" is displayed, go to step 11).
6) Record the value indicated on the display.
flashes.
8) Press the FUNCTION SET YES (+) pushbutton until the value displayed
increases above 99, then release the pushbutton.
a) Requirement: "TEST/EQ MAN STOP" is displayed.
10) “ARE YOU SURE? + -” is displayed. Press and release the FUNCTION SET
YES (+) pushbutton.
"SET TEST/EQ MODE".
pushbuttons simultaneously.
YES (+) pushbutton.
a) Requirement: System output voltage goes to the test/equalize setting.
b) Requirement: MCA "TEST/EQ" indicator goes yellow.
c) Requirement: External test/equalize alarms activate (if available).
"SET FLOAT MODE".
YES (+) pushbutton.
a) Requirement: System output voltage goes to the float setting.
b) Requirement: MCA "TEST/EQ" indicator goes out.
c) Requirement: External test/equalize alarms reset (if available).
Note: The following portion of this procedure takes one hour to complete. If you do
not want to continue with this procedure, go to step 33).
pushbutton until "TEST/EQ MAN STOP" is displayed.
a) Requirement: The display changes to "TEST/EQ HRS = ##", and the

"TEST/EQ HRS =" portion of the display flashes.
25) Press the FUNCTION SET NO (-) pushbutton until the value displayed is
decreased to 1, then release the pushbutton.
YES (+) pushbutton.
"SET TEST/EQ MODE".
YES (+) pushbutton.
d) Requirement: In one hour, the following occurs ...
Requirement: System output voltage goes to the float setting.
Requirement: MCA "TEST/EQ" indicator goes out.
Requirement: External test/equalize alarms reset (if available).
pushbutton until "TEST/EQ HRS = ##" is displayed.
flashes.
39) Press the FUNCTION SET YES (+) pushbutton until the value displayed
increases to the value recorded in step 6), then release the pushbutton. If
"TEST/EQ MAN STOP" was being displayed in step 6), press the FUNCTION
SET YES (+) pushbutton until the value displayed increases above 99.
YES (+) pushbutton.
a) Requirement: MCA displays SYSTEM OK message.
Checking Remote Test/Equalize

Procedure:
2) Apply a remote test/equalize signal to the system.
3) Remove the remote test/equalize signal from the system.
a) Requirement: System output voltage goes to the float setting.
b) Requirement: MCA "TEST/EQ" indicator goes out.
c) Requirement: External test/equalize alarms reset (if available).
Checking Remote High Voltage Shutdown

Caution: This procedure may interrupt power to the load. Perform this test only
during initial startup and checkout of the VPS, or when a load is not
connected to the VPS.
Procedure:
2) Apply and remove a remote high voltage shutdown signal to the system.
a) Requirement: The high voltage shutdown circuit on all PCUs activates to

shut down the PCUs. After approximately four seconds, the restart circuit is
automatically activated to restore PCU operation.
b) Requirement: All PCU "PCU FAIL” indicators go red while the PCUs are
shut down.
c) Requirement: MCA “MAJOR” indicator flashes red while the PCUs are shut
down, if battery is connected to the system.
d) Requirement: MCA displays "1 Alarm Active" while the PCUs are shut
down, if battery is connected to the system. Additional alarm messages
(PCU fail) are displayed as you scroll through the MCA alarm menu.
e) Requirement: External major, rectifier fail, and MCA audible alarms activate
(if available) while the PCUs are shut down.
Checking Emergency Shutdown and Fire Alarm Disconnect
Procedure:
2) Apply an emergency shutdown and fire alarm disconnect signal to the system.
a) Requirement: The PCUs inhibit.
b) Requirement: All PCU “PCU FAIL” indicators go red.
c) Requirement: MCA “MAJOR” indicator flashes red, if battery is connected

to the system.
d) Requirement: MCA displays "2 Alarms Active", if battery is connected to the

system. Additional alarm messages (PCU fail and emergency stop) are
displayed as you scroll through the MCA alarm menu.
(if available).
3) Remove the emergency shutdown and fire alarm disconnect signal from the
system, and on each PCU place the Standby/Operate switch to the "standby"
position and then back to the I "operate" position.
a) Requirement: The PCUs are restored.
b) Requirement: All PCU “PCU FAIL” indicators go out.
c) Requirement: MCA “MAJOR” indicator goes out.
d) Requirement: MCA displays SYSTEM OK message.
e) Requirement: External major, rectifier fail, and MCA audible alarms reset (if
available).
Checking Remote On/Off (TR) (if RS-485 Interface Option is installed)

Procedure:
2) Apply an external Remote On/Off (TR) signal to the system, via a SMART device
(if the RS-485 Interface option is installed).
a) Requirement: PCU operation is inhibited for the PCU that the signal is
directed towards. This can be confirmed by placing a load on the system,
and observing zero output current from this PCU.
3) Remove the Remote On/Off (TR) signal from the system.
a) Requirement: PCU returns to normal operation. PCU picks up share of the

load.
Checking High Voltage Shutdown

Note: This procedure cannot be performed if there are active PCU alarms.
Procedure:

pushbutton until "ADJUSTMENT MENU" is displayed.
5) "ADJUST SYSTEM" is displayed.

pushbutton until "TEST HVS ##.##V" is displayed.
pushbuttons simultaneously. The "TEST HVS" portion of the display flashes.
decreased to below system voltage level, then release the pushbutton.
Note: If the load on the system is light, you have to decrease the value well
below the system voltage level before the requirements are met.
a) Requirement: The high voltage shutdown circuit on all PCUs activates to

shut down the PCUs. After approximately four seconds, the restart circuit is
automatically activated to restore PCU operation.
b) Requirement: All PCU "PCU FAIL” indicators go red while the PCUs are
shut down.
c) Requirement: MCA “MAJOR” indicator flashes red while the PCUs are shut
down, if battery is connected to the system.
d) Requirement: MCA displays "1 Alarm Active" while the PCUs are shut
down, if battery is connected to the system. Additional alarm messages
(if available) while the PCUs are shut down.
Checking AC Fail Alarm

Procedure:
2) Open the external AC disconnect or protective device that supplies power to one
(or more) of the PCUs.
a) Requirement: PCU “AC” indicator goes out.
b) Requirement: PCU “PCU FAIL” indicator goes red.
c) Requirement: MCA “AC” indicator goes red.
d) Requirement: MCA “MINOR” indicator goes red (power removed from one
PCU), or MCA "MAJOR" indicator flashes red (power removed from more
than one PCU).
Note: If there is only one PCU installed, the MCA "MAJOR" indicator flashes
red.
e) Requirement: MCA displays "1 Alarm Active". Additional alarm messages

(AC fail) are displayed as you scroll through the MCA alarm menu.
f) Requirement: External AC fail, minor or major, rectifier fail, and MCA

audible alarms activate (if available).
3) Open the external AC disconnect or protective device that supplies power to a

second PCU (individual PCU feeds only).
c) Requirement: MCA “MINOR” indicator goes out.
d) Requirement: MCA “MAJOR” indicator flashes red.
e) Requirement: MCA still displays "1 Alarm Active", but additional PCU fail
alarm messages are displayed as you scroll through the MCA alarm menu.
f) Requirement: External major, AC fail major, and rectifier fail alarms activate
(if available).
4) Return both external AC disconnects or protective devices to the ON position.
a) Requirement: PCU “AC” indicators on both PCUs go green.
b) Requirement: PCU “PCU FAIL” indicators on both PCUs go out.
c) Requirement: MCA “AC” indicator goes green.
d) Requirement: MCA “MAJOR” indicator goes out.
e) Requirement: MCA displays SYSTEM OK message.
f) Requirement: External AC fail, AC fail major, minor, major, rectifier fail, and
MCA audible alarms reset (if available).
Checking PCU Fail Alarm

Procedure:
2) Place the Standby/Operate switch on a PCU installed in the system to the

"standby" position.
c) Requirement: MCA “MINOR” indicator goes red.
Note: If there is only one PCU installed, the MCA "MAJOR" indicator flashes
red.
d) Requirement: MCA displays "1 Alarm Active". Additional alarm messages

e) Requirement: External rectifier minor, minor, rectifier fail, and MCA audible
alarms activate (if available).
3) Place the Standby/Operate switch on another PCU installed in the system to the
"standby" position.
d) Requirement: MCA “MAJOR” indicator flashes red.
e) Requirement: MCA still displays "1 Alarm Active", but additional PCU fail
alarm messages are displayed as you scroll through the MCA alarm menu.
f) Requirement: External rectifier major, major, and rectifier fail alarms

activate (if available).
4) Return both Standby/Operate switches to the I "operate" position.
a) Requirement: PCU “AC” indicators on both PCUs go green.
b) Requirement: PCU “PCU FAIL” indicators on both PCUs go out.
c) Requirement: MCA “MAJOR” indicator goes out.
d) Requirement: MCA displays SYSTEM OK message.
e) Requirement: External rectifier minor, rectifier major, minor, major, rectifier

fail, and MCA audible alarms reset (if available).
Checking Open Sense Alarm

Procedure:
2) Place the OUTPUT BREAKER on a PCU installed in the system to the 0 "off"
position.
a) Requirement: PCU “OPEN SNS” indicator goes yellow.
c) Requirement: MCA “MINOR” indicator goes red.
Note: If there is only one PCU installed, the "MAJOR" indicator flashes red.
d) Requirement: MCA displays "1 Alarm Active". Additional alarm messages

(open sense) are displayed as you scroll through the MCA alarm menu.
3) Return the OUTPUT BREAKER to the I "on" position.
a) Requirement: PCU “OPEN SNS” indicator goes out.
b) Requirement: PCU “PCU FAIL” indicator goes out.
d) Requirement: MCA displays a SYSTEM OK message.
alarms reset (if available).
Checking Fuse Alarm/Circuit Breaker Alarm

Procedure:
2) Ensure that all circuit breakers (if installed) are in the ON position.
3) Remove an alarm-type fuse from a fuseholder located inside a VPS Distribution

Cabinet Assembly, and replace with a known open fuse.
a) Requirement: MCA “MAJOR” indicator flashes red.
b) Requirement: MCA displays "1 Alarm Active". Additional alarm messages

(fuse alarm/circuit breaker alarm) are displayed as you scroll through the
MCA alarm menu.
c) Requirement: External fuse alarm/circuit breaker alarm, major, and MCA

4) Replace the open fuse with a known good fuse.
a) Requirement: MCA “MAJOR” indicator goes out.
b) Requirement: MCA displays SYSTEM OK message.

audible alarms reset (if available).
5) Perform steps 3) and 4) for each remaining alarm-type fuse located inside the
VPS Distribution Cabinet Assembly.
6) Perform steps 3) through 5) for any additional VPS Distribution Cabinet

Assembly.
7) Remove a TPA distribution fuse (if installed) from the fuseblocks located inside a
VPS Distribution Cabinet Assembly, and replace with a known open fuse.
a) Requirement: The indicator located on the fuseblock goes red.
b) Requirement: MCA “MAJOR” indicator flashes red.
c) Requirement: MCA displays "1 Alarm Active". Additional alarm messages

MCA alarm menu.
d) Requirement: External fuse alarm/circuit breaker alarm, major, and MCA

a) Requirement: The indicator located on the fuseblock goes out.
b) Requirement: MCA “MAJOR” indicator goes out.
c) Requirement: MCA displays SYSTEM OK message.
d) Requirement: External fuse alarm/circuit breaker alarm, major, and MCA

9) Perform steps 7) and 8) for each remaining TPA distribution fuse (if installed)
located inside the VPS Distribution Cabinet Assembly.
Assembly.
11) Remove an alarm-type fuse from a subsystem (if subsystem installed).
a) Requirement: MCA "MAJOR" indicator flashes red.

MCA alarm menu.

a) Requirement: MCA "MAJOR" indicator goes out.

13) Perform steps 11) and 12) for each remaining alarm-type fuse located in the
subsystem.
Note: The following procedure is to be used only with circuit breakers that provide
an alarm indication when manually placed to the OFF (open) position.
Electrical trip alarm circuit breakers cannot be easily tested in the field.
14) Place a distribution circuit breaker located inside a VPS Distribution Cabinet
Assembly (if installed) to the OFF position.

MCA alarm menu.

15) Place the circuit breaker back to the ON position.

16) Perform steps 14) and 15) for each remaining distribution circuit breaker (if
installed) located inside the VPS Distribution Cabinet Assembly.
Assembly.
18) Place a distribution circuit breaker located on a subsystem (if installed) to the
OFF position.

MCA alarm menu.

19) Place the circuit breaker back to the ON position.

20) Perform steps 18) and 19) for each remaining distribution circuit breaker located
on the subsystem.
Checking System High Voltage Alarm 1

Procedure:

"ADJUST ALARMS".
7) "SYS HV1 = ##.##V" is displayed.
pushbuttons simultaneously. The "SYS HVS =" portion of the display flashes.
YES (+) pushbutton.
b) Requirement: MCA displays a high voltage alarm 1 alarm message. To

view, press and release the FUNCTION SET YES (+) and NO (-)
pushbuttons simultaneously, then press and release the FUNCTION SET
ENTER pushbutton.
c) Requirement: External high voltage alarm 1, major, and MCA audible

13) If the alarm message was viewed in b) above, press and release the FUNCTION
SELECT DOWN arrow pushbutton to display "FUNCTION MENU". Press and
release the FUNCTION SET ENTER pushbutton. Repeatedly press and release
the FUNCTION SELECT DOWN arrow pushbutton until "ADJUSTMENT MENU"
is displayed. Press and release the FUNCTION SET ENTER pushbutton. Press
and release the FUNCTION SELECT DOWN arrow pushbutton to display
"ADJUST ALARMS". Press and release the FUNCTION SET ENTER
pushbutton. "SYS HV1 = ##.##V" is displayed.
14) With "SYS HV1 = ##.##V" being displayed, press and release the ALARM
CUTOFF and FUNCTION SET ENTER pushbuttons simultaneously.
15) Press the FUNCTION SET YES (+) pushbutton until the value displayed is
increased to the value recorded in step 8) or to the required value for your site,
then release the pushbutton.
YES (+) pushbutton.
b) Requirement: External high voltage alarm 1, major, and MCA audible

Checking System High Voltage Alarm 2

Procedure:

"ADJUST ALARMS".
"SYS HV2 = ##.##V".
pushbuttons simultaneously. The "SYS HV2 =" portion of the display flashes.
YES (+) pushbutton.
b) Requirement: MCA displays a high voltage alarm 2 alarm message. To

ENTER pushbutton.
c) Requirement: External high voltage alarm 2, major, and MCA audible

pushbutton. Press and release the FUNCTION SELECT DOWN arrow
pushbutton to display "SYS HV2 = ##.##V".
14) With "SYS HV2 = ##.##V" being display, press and release the ALARM CUTOFF
and FUNCTION SET ENTER pushbuttons simultaneously.
YES (+) pushbutton.
b) Requirement: External high voltage alarm 2, major, and MCA audible

Checking System Battery On Discharge Alarm

Procedure:

"ADJUST ALARMS".

pushbutton until "SYS BOD = ##.##V" is displayed.
pushbuttons simultaneously. The "SYS BOD =" portion of the display flashes.
increased to above system voltage level, then release the pushbutton.
YES (+) pushbutton.
b) Requirement: MCA displays a battery on discharge alarm message. To

ENTER pushbutton.
c) Requirement: External battery on discharge, major, and MCA audible

pushbutton. Repeatedly press and release the FUNCTION SELECT DOWN
arrow pushbutton until "SYS BOD = ##.##V" is displayed.
14) With "SYS BOD = ##.##V" being displayed, press and release the ALARM
decreased to the value recorded in step 8) or to the required value for your site,
YES (+) pushbutton.
b) Requirement: External battery on discharge, major, and MCA audible

Checking System 50% Battery On Discharge (Very Low Voltage) Alarm

Procedure:

"ADJUST ALARMS".

pushbutton until "SYS 50% = ##.##V (VERYLOVOLT = ##.##V)" is displayed.
pushbuttons simultaneously. The "SYS 50% = (VERYLOVOLT =)" portion of the
display flashes.
YES (+) pushbutton.
b) Requirement: MCA displays a 50% battery on discharge (very low voltage)

alarm message. To view, press and release the FUNCTION SET YES (+)
and NO (-) pushbuttons simultaneously, then press and release the
FUNCTION SET ENTER pushbutton.
c) Requirement: External 50% battery on discharge (very low voltage), major,

and MCA audible alarms activate (if available).
arrow pushbutton until "SYS 50% = ##.##V (VERYLOVOLT = ##.##V)" is
displayed.
14) With "SYS 50% = ##.##V (VERYLOVOLT = ##.##V)" being displayed, press and
simultaneously.
YES (+) pushbutton.
b) Requirement: External 50% battery on discharge (very low voltage), major,

and MCA audible alarms reset (if available).
Checking System Current Alarm

Procedure:

"ADJUST ALARMS".

pushbutton until "SYS CURR = ####A" is displayed.
pushbuttons simultaneously. The "SYS CURR =" portion of the display flashes.
decreased to below system output current level, then release the pushbutton.
YES (+) pushbutton.
a) Requirement: MCA "MINOR" indicator goes red.
b) Requirement: MCA displays a system current alarm message. To view,

press and release the FUNCTION SET YES (+) and NO (-) pushbuttons
simultaneously, then press and release the FUNCTION SET ENTER

pushbutton.
c) Requirement: External system current, minor, and MCA audible alarms

activate (if available).
arrow pushbutton until "SYS CURR = ####A" is displayed.
14) With "SYS CURR = ####A" being displayed, press and release the ALARM
YES (+) pushbutton.
a) Requirement: MCA "MINOR" indicator goes out.
b) Requirement: External system current, minor, and MCA audible alarms

reset (if available).
Checking Subsystem (if subsystem installed) High Voltage Alarm

Procedure:

"ADJUST ALARMS".

pushbutton until "SUB HV = ##.##V" is displayed.
pushbuttons simultaneously. The "SUB HV =" portion of the display flashes.
YES (+) pushbutton.
b) Requirement: MCA displays a subsystem high voltage alarm message. To

ENTER pushbutton.
c) Requirement: External major and MCA audible alarms activate (if

available).
arrow pushbutton until "SUB HV = ##.##V" is displayed.
14) With "SUB HV = ##.##V" being displayed, press and release the ALARM
YES (+) pushbutton.
b) Requirement: External major and MCA audible alarms reset (if available).
Checking Subsystem (if subsystem installed) Low Voltage Alarm

Procedure:

"ADJUST ALARMS".

pushbutton until "SUB LV = ##.##V" is displayed.
pushbuttons simultaneously. The "SUB LV =" portion of the display flashes.
YES (+) pushbutton.
b) Requirement: MCA displays a subsystem low voltage alarm message. To

ENTER pushbutton.
c) Requirement: External major and MCA audible alarms activate (if

available).
arrow pushbutton until "SUB LV = ##.##V" is displayed.
14) With "SUB LV = ##.##V" being displayed, press and release the ALARM
YES (+) pushbutton.
b) Requirement: External major and MCA audible alarms reset (if available).
Checking Subsystem (if subsystem installed) Current Alarm

Procedure:

"ADJUST ALARMS".

pushbutton until "SUB CURR = ####A" is displayed.
pushbuttons simultaneously. The "SUB CURR =" portion of the display flashes.
decreased to subsystem output current level, then release the pushbutton.
YES (+) pushbutton.
a) Requirement: MCA "MINOR" indicator goes red.
b) Requirement: MCA displays a subsystem current alarm message. To view,

press and release the FUNCTION SET YES (+) and NO (-) pushbuttons
simultaneously, then press and release the FUNCTION SET ENTER
pushbutton.
c) Requirement: External minor and MCA audible alarms activate (if

available).
arrow pushbutton until "SYS CURR = ####A" is displayed.
14) With "SUB CURR = ####A" being displayed, press and release the ALARM
YES (+) pushbutton.
a) Requirement: MCA "MINOR" indicator goes out.
b) Requirement: External minor and MCA audible alarms reset (if available).
Checking Low Voltage Disconnect (if furnished)
Procedure:

"ADJUST LVD".
7) "LVD1A = ##.##V" is displayed (if installed). If you are checking the other low
voltage disconnect circuits, repeatedly press and release the FUNCTION
SELECT DOWN arrow pushbutton until the respective low voltage disconnect
circuit name is displayed (LVD1B, LVD2A, LVD2B, LVD3A, or LVD3B).
Warning: Performing the next step inhibits the operation of the low voltage
disconnect circuit, and if a load contactor is furnished, prevents
disconnection of battery and system output from the controlled
load(s) if a low battery voltage condition occurs. Also, if 582120100
List V or W is furnished (low voltage disconnect battery contactor),
prevents disconnection of battery from the system if a low battery
voltage condition occurs.
9) Place the NOR/INH switch to the INH position. This switch is located inside the
VPS Distribution Cabinet Assembly. This prevents accidental disconnection of
battery and system output from the controlled load(s) if a load contactor is
furnished and accidental disconnection of battery from the system if 582120100
List V or W (low voltage disconnect battery contactor) is furnished while
performing this procedure.
a) Requirement: The low voltage disconnect "inhibit" indicator illuminates.
pushbuttons simultaneously. Portion of the display flashes.
YES (+) pushbutton.
a) Requirement: After a 5-10 second delay, the MCA displays a low voltage
disconnect alarm message. To view, press and release the FUNCTION SET
YES (+) and NO (-) pushbuttons simultaneously, then press and release the
FUNCTION SET ENTER pushbutton.
b) Requirement: External LVD alarm activates (if available).
arrow pushbutton until "LVD1A = ##.##V", or the respective low voltage
disconnect circuit, is displayed.
15) With "LVD1A = ##.##V", or the respective low voltage disconnect circuit, being
displayed, press and release the ALARM CUTOFF and FUNCTION SET ENTER
YES (+) pushbutton.
19) Perform the following steps if the low voltage disconnect circuit is set for manual
reconnect. If set for automatic reconnect, there is a 15-20 second delay before
the LVD circuits reconnect.
a) With "## ALARMS ACTIVE" being displayed on the MCA Interface Pad,
press and release the FUNCTION SET ENTER pushbutton.
b) Press and release the FUNCTION SELECT DOWN arrow pushbutton to

display "ALARM LVD ACTIVE".
c) Press and release the FUNCTION SET ENTER pushbutton.
d) Repeatedly press and release the FUNCTION SELECT DOWN arrow

pushbutton until the low voltage disconnect circuit being checked is displayed
("RECONNECT LVD**", **=the designation of the low voltage disconnect
circuit).
e) To reconnect the low voltage disconnect circuit being displayed, press and
simultaneously.
f) "ARE YOU SURE? + -" is displayed. Press and release the FUNCTION SET
YES (+) pushbutton. The low voltage disconnect circuit reconnects.
Caution: DO NOT perform the next step until you verify that there are NO low
voltage disconnect alarms active. If the next step is performed when
low voltage disconnect alarms are active, battery and system output
will disconnect from the controlled load(s) if a load contactor is
furnished, and/or battery will disconnect from the system if a low
voltage disconnect battery contactor is furnished.
20) Place the NOR/INH switch to the NOR position. This switch is located inside the
VPS Distribution Cabinet Assembly.
a) Requirement: The low voltage disconnect "inhibit" indicator extinguishes.
22) Repeat this procedure for the other low voltage disconnect circuits installed.
Checking System Status

Procedure: Observe the status of the display and indicators located on the PCUs, MCA
Interface Pad, and VPS Distribution Cabinet Assembly. If the system is operating
normally, the status of these are as follows.
MCA Interface Pad:
b) Requirement: MINOR indicator off.
c) Requirement: MAJOR indicator off.
d) Requirement: AC indicator green.
e) Requirement: TEST/EQ indicator off.
f) Requirement: ALARM CUTOFF indicator off.
PCU:
a) Requirement: OPEN SNS indicator off.
b) Requirement: FAN FAIL indicator off.
c) Requirement: PCU FAIL indicator off.
d) Requirement: AC indicator green.
VPS Distribution Cabinet Assembly:
a) Requirement: Low Voltage Disconnect INHIBIT indicator off (if furnished).
Final Step
Close the front door on each VPS Intelligence and Expansion Shelf, and each VPS
Distribution Cabinet Assembly. The door can be shut without turning the captive
fasteners.
APPENDIX (a record of changes made to this document)

Change
Issue Number Description of Change
(ECO)
AA LLP035364 New, was p/o Section 5705.
AB LLP200086 Load Share Alarm Added. New Relay Set Added.
AC LLP201873 MCA Ethernet Interface Option added. TXM added.
Emerson Network Power, Energy Systems, North America, Inc.

1122 F Street / Lorain, Ohio 44052-2293 / (440) 288-1122
In Canada:
Emerson Electric Canada Limited
122 Edward St. / St. Thomas, Ontario N5P 1Z2 / (519) 637-4900
In Mexico:
Emerson Network Power de Mexico, S.A. de C.V.
Apartado Postal 77001 / Mexico 10 D.F., MX 11200 / (525) 576-8277

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Section 5920

VORTEX® POWER SYSTEM (VPS)

Spec. No.: 582120100

The Emerson logo is a trademark and

Lorain® is a registered trademark of Emerson

Vortex® is a registered trademark of Emerson

The products covered by this instruction manual are manufactured and/or

If we can be of any further assistance to you,

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Page 2 of 2 Static Warning

JACK RINGER EQUIVALENCE FCC REGISTRATION NUMBER

FCC Information Page 1 of 2

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Page 2 of 2 FCC Information

CHAPTER 2 SETTING VPS WIRING OPTIONS ................................................................... 2-1

Table of Contents Page i

VPS Distribution Cabinet Assembly Internal/External Voltage Sensing

CHAPTER 3 MAKING ELECTRICAL CONNECTIONS......................................................... 3-1

Page ii Table of Contents

Shelf(s) Spec. Nos. 588700701, 588700801, 588703600, and 588703700,

Table of Contents Page iii

APPENDIX (a record of the changes made to this document)

Page iv Table of Contents

Note: A Battery Thermal Runaway Management System may be furnished. For

Chapter 1. Installing VPS Page 1-1

INSTALLATION ACCEPTANCE CHECKLIST

Relay Racks Mounted to the Floor

Battery Charge Digital Temperature Compensation Probe Mounted (if required)

Analog Battery Charge Temperature Compensation Module Mounted (if required)

TPL-Type Fuses Installed in VPS Distribution Cabinet Assembly (if required)

VPS LEL1-Type Circuit Breaker Modules Installed in VPS Distribution Cabinet

Modem, RS-232, RS-232/Modem, RS-485, or Ethernet MCA Interface Option

VPS Intelligence and Expansion Shelf PCU Mounting Positions Identification

VPS Intelligence and Expansion Shelf Internal/External System Voltage Meter

VPS Distribution Cabinet Assembly Internal/External Voltage Sensing and

Page 1-2 Chapter 1. Installing VPS

VPS Distribution Cabinet Assembly Shunt POD System/Subsystem Identification

VPS Distribution Cabinet Assembly Low Voltage Disconnect Circuit Card

Modem or RS-232/Modem Option (if furnished) "Number of Rings before Answer"

RS-232/Modem Option (if furnished) "RS-232 Hardware Handshake" Jumper Set

Battery Charge Temperature Compensation Module (if used) Maximum Voltage

Grounding Connection (Frame Ground) Made

AC Input Grounding Connections to each PCU Shelf Made

AC Input Connections to each PCU Shelf Made

External Alarm, Reference, and Control Connections Made

MCA Interface Option Cable Connection(s) Made (if installed)

Chapter 1. Installing VPS Page 1-3

Alarm, Reference, and Control Interconnections between Multiple VPS Distribution

Load Connections Made

Battery Connections Made

System Started, Configured, and Checked

Page 1-4 Chapter 1. Installing VPS

MOUNTING THE RELAY RACKS

Chapter 1. Installing VPS Page 1-5

MOUNTING A BATTERY CHARGE DIGITAL

1) Mount the Battery Charge Digital Temperature Compensation Probe to any

MOUNTING A TXM (MULTIPLE PROBE

MOUNTING AN ANALOG BATTERY CHARGE

The battery charge temperature compensation module is to be mounted on or near the

1) Mount the battery charge temperature compensation module to any suitable

Page 1-6 Chapter 1. Installing VPS

INSTALLING VPS FUSEHOLDER MODULES (TPA-TYPE)

LOAD A Bus may be arranged with battery disconnect fuse(s)/circuit breakers.